ok guys and gals, I have an 03 rancher 350 manual shift, the shift shaft that the gear shifter fits on broke off even with the case. the shaft itself is only 36.00, can you put this in with the motor still on the atv or do I have to take the motor off? and also can it be done with out pulling the crankcase apart? I have heard some say you can do it on the atv, and then others have said you have to pull the head and cylinder jug off and split the cases. just hate to take it all apart, it don't smoke or anything. one more question, how do you start it in gear? I know there is one wire you can ground and it will start but don't remember, the first time it broke on me we were 12 miles from the truck. I called the local repair shop and they told me how to start it, we ended up welding the shifter it lasted two years then broke again, had it welded today and lasted 20 minutes.

 

It is years since I did it, so I am not certain, but I think the bolt holding it in is in the case behind the alternator, so you don't need the engine out. You take the pull start and alternator off, then the case behind it, that may be difficult as I'm not sure it comes off with the flywheel in place, and the flywheel puller is a special tool. Anyway, I think once this case is off, the bolt holding the lever onto the shaft can be removed. Check the timing chain isn't slack while you have the case off, as they often are, and you would have to remove this case (and the flywheel) to change it. The rotary switch which tells the instrument panel which gear it is in, has to be lined up properly with the shift drum when you put the case back. Get it wrong and it will only start in gear, and the neutral & reverse lights come on when in forward gears.