Hello all! I just rebuilt a 2001 Bayou 220 with new rings, 1mm over piston, new gaskets, timing chain, severe cleaning and a professional head job with new valves. Anyway I rebuilt the whole engine to check tolerances and clean everything up. I used the shop manual religiously, labeled everything perfectly and took lots of pictures. The engine runs like a top but will not shift when running. When it is off I can shift into all the gears, even start it in gear and drive it around.

An ATV "expert" told me I put the transmission together wrong. Now I used the shop manual religiously, used the pictures and cold hard logic. Now everything really only fits and works one way and I KNOW I put it together right. Now I just can't wrap my head around it being the transmission, I am thinking more something wrong with the clutch system.

Any thoughts?
Thanks!

 

if you can sight when off, then you PROBABLY have everything together right, but could have missed the triangle or the spring under the clutch cover, BUT,...

adjust the clutch...

take off the 3 screws on the rightside, removing a 2.5x4 or so panel...

loosen nut a little bit...

turn screw all the way to the right, till it gets a little firm...

turn back to the left till it gets a little firm

i turn back 1/4 turn to the right, and then tighten the nut back down...

replace the cover, drive away

 

So I'm not alone in assuming the transmission is correct? Yes! I will try adjusting the clutch like you said when I got home from work.

I wanted some other opinions before I tore the engine down. I was so let down when it didn't work quite right when I put it together as this is my first major engine project.

Thanks all!

 

other thing could be, did you put the clutch together RIGHT? took me a couple tries the first time .. look at the manual, on the alighment "o"s