Hi - I got a 81 ATC 110. Picked it up not running for 10 years and was able to get it going with a little elbow grease and apple cider vinegar. After going through most of it the only problem area I have is a the shift lever literally moves 10 inches before it will shift either up or down. It does shift smoothly throughout the gears in both high and low although it's easier to shift the lever with my hand when it comes to down shifting just because of how far i need to move the lever.

Anyone have an idea of where to begin with this? From what I'm finding it could be a badly worn shift shaft lever. Just looking to understand where to start and what I'm getting myself into.

 

Looking through the parts diagram I'm fairly confident the issue lies between the gear shift spindle and the gear shift arm. The other area would be the shift forks but I guess I can't say I've seen them worn that badly before. Seems to be more common to break them than to wear them out. Hopefully the clutch removal tool comes in this weekend so I'm able to dive into the issue.

 

Quick update: I found the problem and it was the guy between the seat and the throttle...

I took the right side cover off to find out that the shaft isn't moving on the right side which takes me to left hand side. You guessed it, the shifter lever is stripped and the splines are pretty well torn up. I'd looked over that part before to...maybe i should get my eyes checked. Anyways, my plan is to weld a pipe onto the end of the shifter lever which will slide over the shifter shaft then put a couple holes through the pipe and shaft to run a bolt through it as a temporary fix. Then replacing the shaft and lever when I get them.