I was riding around and my clutch thats inside the motor had been broken for a while so i have to slowly let it in gear so it wont stall. So just last week i was going up a big hill and i had the motor reving high and the gear kinda half way in, just enough to go without stalling, And all of a sudden i couldnt go forward anymore. When i put my quad in gear it makes the noise like it goes into gear but when you hit the gas it doesnt go anywhere. I need help. What did i break? How expensive is it gonna be to fix?? My quad is shaft driven. and its was made in 03. It has 5 gears. Please help me.

 

well, i'm wondering if your 03 is like my 07. you don't need a clutch to shift. i'm wondering if you should leave it shutdown, put it in 1st gear, try to turn the drive shaft to see of the output shaft is broken or stripped. what gear were you in when it screwed up? try putting it in that gear and pushing the quad to see if the gear even grabs while shutdown. let me think some more on it. well i thought some more, i may be way off base, but the clutch/centrifugal clutch could be slipping or something else is happening there. i don't know how to adjust that. maybe the tranny experts will weigh in. sorry.

 

Yes tht is right, i dont need a clutch to shift, the clutch is internal and it does it by itself. I was in first gear when it broke and when it broke i didnt hear any breaking or clanking noise and when i put it in gear when the motor is off it still rolls. I even tried going in reverse and it didnt work. It doesnt even slow it down, its like its still in neutral but when i shift in gear the neutral light goes off and it makes a clank noise like it usually does.

 

i wonder if it has a shifting fork on the inside that has come loose or broken off and is not in a dangerous position to cause clanking or is just bent down where it won't engage anything. just a theory.

 

Hmmm. Ok thanks alot for your help, at least now i have some ideas of what could be the problem. Its sucks because i dont even have the money to fix it right now. So its gonna be stuck in the garage for awhile.

 

it could be the clutch springs for the 3 weights (steel pucks) infront of the clutch plates. their is 3 springs that hold these in a triangle shape. when mine break, usually just one it chugs and stalls like a manual clutch. just my two cents

 

If I'm not mistaken, that quad has 2 clutches. One is the gear change clutch and the other is a centrifugal clutch. It's probably the centrifugal clutch that is bad. That's easier to fix.

 

It turns out both of my clutches were completely worn out. The guy said he had never seen a clutch this burnt up and worn out. I Fried everything on my clutches. The guy saved them so i can see and the plates that are in there were just soo black and the metal was just all junk and worn down. But anyways, it cost about 600 dollars to replace both. I only remember the one clutch name and that was the Centrifugal clutch, i dont remember the name of the other one. Now i got my qaud and it works soo much better and it also seems faster, Thanks for all your ideas.

 

a $600.00 investment into a $4000.00 machine sounds like a good trade off because it's hard to put a price tag on fun and happiness! at least that's the way i look at it. glad you got it going. happy trails.

 

still sounds like a stripped shaft, so just follow the other directions, prop the back off the ground, put it in gear and try to spin the tires, or roll it in gear when the bike is not running, if the tires do not turn, great something simple, if they do, stripped output shaft, a bit more work for that than a few clutch pieces, good luck