trx450es 2001

My trany stopped shifting up past 1st gear, will go from rev to neutral and 1st to neural, but wont go to 2nd or beyond. So i took the whole thing apart by the Haynes manual, following all steps and procedures. This morning i got to the case cracking and removed the gears. By procedure, and suggested in the manual, I bent out a coat hanger and placed the gears and parts onto the hanger in the order i removed them from the shaft. After i had them all off, i bent out another hanger and hung it from the garage ceiling. I began moving one part at a time from one hanger to the other carefully inspecting them for chipped teeth and discoloration.

now the disaster.... the LAST gear that i placed in the hoop caused the thing to crash to the workbench and gear, washers, bushing and all flew everywhere..... after i cried a little, i picked up the parts into a pile and began trying to sort it out. 2 hours later ive made no progress.

The gears have no labels to identify them, the washers and bushings are the same. The pictures in the Haynes book and on bikebandit.com are not detailed enough to reassemble. So now what? I can start counting the teeth per gear... compare to bikebandits part list.. and use their schematic for the gear order, but not the bushings and washers, ect. There is a finite number of combinations, Right?

Any suggestions aside from buying another engine

 

BTW i did find badly worn fingers on both shift forks. This is my original problem. Replacement cost : about $120 for both parts. Cost to put Humpty Dumpty back together again : pricelesssss (i wish)

 

Sorry for the mishap, sounds like something I would do (if i was ever courageous enough to take it apart). Hope you get it back together.

Also, sorry I can't offer help, just sympathy!!

 

The Honda transmission section is better .. PM your email and I will email you the section ...

 

Hey rand2002, did you get this figured out yet?

 

no i haven't. and i haven't dedicated much time to direct puzzle fixing since Sunday. Just looking for a good pic or diagram.
I was looking for an email from HondaMechanic sending me the transmission section of the Honda book.
my email open email is tonybluesteel@yahoo.com
I sent HondaMechanic a different address in a PM. Either is fine, i just try to keep one more private and this one can be publicly posted. tonybluesteel@yahoo.com

Any and all help is appreciated.

 

I resent it this morning to this address .. I sent it yesterday at noon so you should have gotten it , I get a bounce message from my ISP if emails don't go and I haven't gotten one so you should receive it .. Maybe your email put it in your junk folder or blocked it ..


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This is a picture of the TRX450S/FM countershaft .. When you receive the shop manual section you will be able to assemble the shaft/s .. Just use a marking pen and mark a tooth , then count the teeth and write on the gear the tooth count and which gear it is .. Then assemble using the picture as to which gear goes where and what direction it goes.. ..

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my tranny also screwed up it is stuck in a high gear like 4 or 5. the tires well only spin when rolled down a hill, the bike well not start. im not looking to fix the tranny just trying to buy a new one or cheaper tranny to fit a 2007 honda 400ex. i really want a reverse. if you can help me thx a bunch if not its cool

 

Mechanic, you once again have saved the day and my wallet and maybe something with my marriage.

A Million Thanks !

 

lllllllloooooooooooollllllllll !!!