Thanks for trying trailblazermudrunner. Anybody else have any tips? I'm going to start working on it tomorrow evening. I might just have to use a big hammer, a sawzall, and some zip ties lol.

 

Does anyone know if I'll have to remove the whole clutch assembly to get the tranny out or just the furthest back part? I have it mostly stripped down and ready to come out, but it just got too late to deal with it tonight.

 

So I finally got the tranny out and split. I looked and looked at it, but nothing seems to be wrong. I am stumped. All the teeth on the gears are there, everything moves freely, the chain seems to be in good shape, etc... What do I do now? My ATV is in 100s of pieces and I have yet to find the problem. Anyone have an insight?

 

is the out put shaft spline in goos shape where the gear goes on. is the shifting fork bent in a way not to let it shift all the way. i was looking at a break down and dont see any key ways that could be broke. the only other thing that i can see in the break down is the 2 dogs(one on each end)on the input shaft that mesh the gears in might be broke. just take a look at them. best i can do for ya. good luck and let us know.

 

I checked everytrhing over again and everything looked good, except for the shifting fork. I cleaned it all up really good and looked at it and it looks like one of the forks is bent just a little bit. When compared with the one beside it you can see it for sure. Would this probable be the cause of the problem? How do I get the shift fork out? How much would a new one cost me? It seems like there is hope for me afterall. Thanks!

 

this is off ronnies.com
FORK,SHIFT,HR
3233231 1 $141.95
not sure how it would apart unless i could see it myself. any way you could rebend it back or is it too weak or to badly bent. some one else jump in on this.

 

Wow, $142! That is more that I thought it would be. I might try to straighten out. I guess i can't make it any worse. I just don't want to think it is good to go, put it all back together to find that i didn't straighten it right. I forgot to mention on my previous post that I could see where metal has rubbed against the shift fork where it is bent, so that is probably my problem

 

could be. just remeber that the gear case is only alum, or white metal and breaks easy.

 

So here's a funny story. I got everything put bacxk together and ready to try out. Put it in drive and go 15 feet before it stops. I look around because something is obviously still wrong. I notice that the front sprocket fell off the output shaft. It comes down to the c clip that I put on is just slightly too large and allows the new front sprokcet to fall off the shaft. I'm going to get a smaller c clip and that should do the trick. Oh well, I learned a lot and have a very clean tranny now.

 

wow, that kinda of sucks but at least it works now, and you learned something.