I have a 2004 700 efi sportsman motor in a buggy, i put an epi clutch kit in it and now i can not shift gears enless i turn the motor off. I think what is happening is the clutch is engaging really early. Has this happen to anyone else, and do you know a fix??

 

Sounds like your clutches may be out alignment,especially if rear clutch is turning at idle,will cause hard shifting or not able to change gears with out killing machine. Also check play on one way bearing on front clutch,should have about .020 clearance between clutch sheaths when moved back and forth. Common for wear on fiber washer on inside sheath of one way to cause problems along with the metal space that wears down inside the front clutch cap(if you have a parts break down will help) Check alignment first, usually belt is touching one side of front sheath causing rear clutch to constantly spin (when adjusted correctly rear clutch will not turn or will barely try to. Shims behind rear clutch can be removed or added to help alignment.Belt should ride close to center of front clutch. Another thing to check is front motor mount for separation,can pry up on mount and see if bad. Plus are you running stock or after market belt? Can make a difference! BUGGY?? atv or what?? OPT

 

also check what rpm engine is idling, mabe too fast

 

Thanks guys, i will look at things this weekend..

 

What kind of buggy did you put it in?



And going by the thread title, I'd say wait till she's at least 17 and you can outrun her dad.

 

sounds like it might also be a bad ebs bushing or fiber washers in the primary clutch if it has ebs. most of the time a clutch kit makes a higher engaugement and not sooner. imo

 

The one way bearing looks to have more then .02 play between the shealths. But it spins clockwise fine with no drag and will not spin at all counter clockwise. The belt came with the epi kit. The rear clutch does spin at idle (about 1070pm). I did remove one of the rear clutch spacers that did not change anything so i put it back. I did not check the aliment before i took it all apart (dumb me). Should i put all the old parts back in and see what happens???

 

the way I alighn clutches is, take belt cover off, start motor, give it somethrottle to spin clutches, let it idle , see if belt is rubbin on one side or the other of primary, remove or add shims behind secondary to center belt on primary, if its the EBS washers you need special toools to get the clutch apart