I have a 07 800 EFI with 49 hours on the clock. The gear shift is smooth with the engine off, but with the engine running shifting gear takes excessive force. This ATV has a heavy duty clutch fitted. Any ideas or help would be appreciated.[img]i/expressions/face-icon-small-confused.gif[/img]

 

Most likely clutch alignment. Check your lower front motor mount there has been a few 07 800 braking there mounts causing misailinment.

 

I have the same experience, even with no clutch creeping. This is what I do: when you switch from H or L to R, try rocking it backwards slightly before shifting, it will go very smooth then. Seems that taking the forward load off the gears helps to shift it into R, and visa versa, taking the rear load off the gears when shiting out of R makes it smooth. My 500 doesn't have this problem.

 

is it grinding, what rpm is it at? should be around 1150 +-. check the front engine mounts as well to make sure there dont broke.

 

Many thanks for the help.

The lower engine mount was sheared and i replaced it myself a couple of months ago (which resulted in the belt snapping)[img]i/expressions/brokenheart.gif[/img][img]i/expressions/face-icon-small-confused.gif[/img]. How do i carry out the 'clutch alignment'?

 

I removed the belt cover and the belt is engaged (driving) when the engine is at idle speed (1100 rpm). Any ideas ?

 

you would need a clutch alignment tool to make sure it was lined back up. is the belt sitting in the middle or to 1 side in the primary clutch? my clutch will turn while idleing in neutral a little bit just from the friction on the belt being rubbed. imo.