I bought a 2001 Scrambler 500 4x4 this weekend. The guy selling it was honest about a few issues with the bike and let it go for not much money. The three issues with the bike are:

1) won't go into forward
2) electric starter doesn't work
3) choke cable is stuck

The choke cable and starter I think aren't a big deal. The starter was replaced by the dealer last year. Now it just makes a click and does not turn the motor over. I can start the engine with the pull start. Anyway, let's worry about the gearcase first. I pulled the plastic and the clutch cover to get a look at things. I unhooked the shift linkage and tried to select the forward gear using the lever on top of the gearcase. I can get reverse and nuetral but no forward. From looking at it I think my first course of action should be to remove the gearcase and open it up. I've ordered the shop manual and it should be here in the next few days. Any warnings or suggestions? I'm no stranger working on cars/motorcycles/atvs/etc but asking opinions from people with experience always helps.
Thanks,
Jim

 

You came to the right place. Unfortunately I dont have an answer for you, but someone here will be able to provide some useful information I am sure.

Welcome to the board!

 

I've pulled the stuff around the gearcase that was easy to get off and removed the plastic. I've taken the driven pulley off. My service manual has not arrived yet so I've got some questions.

1) Can I get the gearcase out without removing the belt cover backing plate? I'm talking about the plasitc piece that goes between the motor and gearcase. It looks like you have to remove the clutch unit to get that plate off.
2) Once the mounting bolts are removed will the gearcase come out with the exhaust in place?
3) Is the drive shaft from the gearcase to the front drive unit only removable by removing the gearcase or the front drive unit?

Thanks,
Jim

 

Hey Jim,

did you ever get your shifting problem fixed? I know its been quite a few years but i ran into this problem. I've taken the transmission out and now am about to split it and see for myself. If you could let me know your experience that would awesome! thanks!!!