Motorcycle Repair: 1987 yamaha big bear 350 atv., clutch plates, little shoes

Question
the last time i used my atv. i geared up with no problem now i can't get the gears to go back down to neutral.the atv has no clutch.all the oils are at the right levels. can you tell if there is a easy solution to the problem?

Answer
Hi Rodney,

Your atv has two clutches but that may not
be the problem. One clutch is actually
a centrifugal set of little shoes like
brake shoes. They swing out when the motor speeds
up and start the machine moving.

The other clutch is like a regular clutch
with clutch plates or discs in it.
It releases as you push your
shift lever.

Your machine should shift even if the
clutches are bad when it is not running.

If you rock the machine a little
and push the shift lever it should
shift. If not, it might be something
has broken or come loose inside the
shift assembly under the engine case.

On the opposite side of the engine
from the shift lever is the case
where all the shifter assembly
lies. The shift shaft turns a rachet
type thing and rotates the shift drum
or barrel. This drum has grooves
on it that move the shift forks inside
the transmission. The forks move the gears
into their proper position.

If the gears or forks or drum
is damaged then it requires splitting the
engine.

If it is something on the shifter assembly that is loose
or broken then you can probably repair
if after removing the outer engine cover.

First check your shift lever and linkage
to make sure nothing is bent or hitting
on anything.

Under the engine cover you can
see the shift shaft and various springs
and the drum locater. When you push the
shift lever it should catch on the pins
on the end of the shift drum and rotate it.
One way it shifts up and the other down.
If it doesn't turn the drum you will
not be able to shift.

If you get that working it might solve
the problem. You may need some new shifter parts
or springs etc.

Remember to rock the machine a little
to help it shift when it is not running.

If you cannot get the shift drum to rotate either
way it may be more serious transmission damage
inside.

Luck!
Wayne S.

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