Troubleshooting an ATV that won’t go into gear or won’t shift gears can be quite complicated, but not always. Whether you can address the issue on your own depends on the severity of the problem and your mechanical skill level.
ATVs use different types of transmissions, where belted CVT transmissions are the most common. The possible causes and the steps required to solve the problem depend on the type of transmission your ATV has.
This post covers some of the most common causes if your ATV doesn’t go into gear. It is meant to guide where to begin your troubleshooting, not as a complete repair guide for all ATV transmissions.
The service manual for your specific brand and model will provide more detailed troubleshooting procedures for your transmission issues.
Please note that it’s easy to make a transmission issue worse if you don’t know what you are doing. Some of the repairs require special tools such as a clutch puller or a clutch disassembly tool. If the repair seems intimidating to you or you do not have the right tools, it is recommended that you take the bike to a dealer technician.
Page Contents
We recommend that you begin the troubleshooting by testing whether you can shift gears when the engine is not running. This initial test allows you to narrow down the possible culprits of your gear-shifting issue.
If you can shift gears with the engine off, you know that the gear-shifting mechanism, as well as the inside of the gearbox, most likely works fine.
Gear shifting problems that are only present when the engine is running are usually clutch- or belt-related (Step 3) or caused by a high idle (Step 2). You may find that the bike wants to creep or move forward when in gear at idle. But even without creep, the problem may be with one of these components.
If you are, however, unable to shift gears with the engine off, we recommend you jump straight down to Step 4.
Many ATVs come with an automatic clutch that engages when you apply throttle, and the clutch speeds up. The same principle applies whether you have a wet disc clutch or a dry clutch, as you find on a belted CVT transmission.
If the ATV, for some reason, idles higher than it’s supposed to, it may cause the clutch to engage slightly, putting a small but constant tension to the metal gears inside the gearbox. This pressure on the gears makes the ATV very hard to shift.
Most ATVs should idle around 1100-1200RPM. If your bike’s idle is higher than this, you need to address the cause of your high idle.
For carbureted ATVs, there will be an adjustment screw to set the idle. Your user manual will provide the correct setting for your bike. Adjusting the idle on a fuel-injected ATV is usually a job for a mechanic.
When idling, the primary clutch on a belted CVT transmission is supposed to spin freely without engaging (not pulling on the belt).
This relieves the tension on the gearbox and allows you to shift gears.
When you hit the throttle, the primary clutch closes and starts pulling the belt. The belt makes the secondary (driven) clutch spin, which creates tension between the gears inside the gearbox.
This is how a CVT transmission works:
But when the transmission is not tuned correctly or has a mechanical issue, it may be engaging and spinning the secondary clutch even at idle.
To troubleshoot an issue like this, you need to remove the belt cover to inspect the clutches and see how they behave when the engine runs, both at idle and when revving in neutral.
Please note that the clutches will be spinning at high speeds. Keep your hands and all loose objects clear of clutches to avoid potentially fatal damage.
If the primary clutch is packed with dirt, it may bind or not open enough to release the belt. Now is a good time to pull the clutches for proper cleaning and service.
The springs inside a CVT transmission clutch may weaken over time, preventing the clutch from functioning as it is supposed to. Clutch springs are replaceable, but you may need special tools to pull and disassemble the clutch.
If the motor mount is bad or has come loose, the primary clutch may be out of alignment. Use a pry bar to see if you can lift the whole engine. You should barely be able to see the engine move, if at all.
The drive belt should ride in the clutch assembly center, not touching the primary’s two clutch sheaves. If it does rub against one of the sheaves, it will cause unwanted tension on the belt.
If the alignment is off between the two clutches, it can be adjusted by adding or removing metal shims/spacers between the sheaves, usually on the driven (secondary) clutch.
Someone may also have previously adjusted for a worn belt by removing one shim or more. When installing a new belt, you may need to add those spacers back to prevent binding, leading to gear shifting issues.
If the drive belt is worn too much, it will ride low on the sheaves, causing a slight creep.
We recommend that you only use OEM belts. There are aftermarket belts available that offer better performance and longevity at a smaller price. But slight variations in production tolerances can cause issues such as the clutch engaging too soon.
Aftermarket belts also use a harder compound to make them last longer, which may wear your clutch sheaves over time.
Remove the belt cover. If the belt is shredded, it may have gotten wrapped around the driven shaft, causing it to bind up.
Polaris ATVs with EBS (engine brake system) have components that may wear out in time.
Inspect the EBS fiber washers (one on each side of the EBS bushing) on the primary clutch to see if they are worn out. If the washers are worn, the belt may not ride in the grooves as it should and instead ride one of the sheaves.
Some ATVs with engine brake systems have a primary clutch with a one-way sprag bearing, a so-called one-way clutch. It is supposed to spin freely in one direction and be locked in the other direction. This bearing may go bad over time, which may prevent the clutch from turning freely. It may be hard to tell if the bearing is ok; just a slight drag may cause shifting issues.
In this case, the problem is likely with the gear changing mechanism or the transmission’s internals. Begin by troubleshooting the externals as they are the most accessible.
Some ATVs have adjustable gear linkage.
If not adjusted correctly, the bike will not shift as it should.
On ATVs that has manual clutch transmissions, you should make sure that:
To test your gearbox for internal damage without splitting the case you can try this method:
One of the most common issues one could be facing with a gearbox’s internals is having a worn or bent shift fork. The shift fork is what shifts the gears in place. If it is bent or worn, it can’t push the gears completely in place.
Some ATVs use an oil-sump wet clutch in combination with the dry clutches on the CVT belt transmission. You also have some Honda ATVs with hydrostatic transmissions that use oil to drive the ATV forward.
Here are a few things to check out whenever any of these types of ATVs won’t go into or shift gears.
Make sure the oil level is correct or the bike may not shift as it should.
If the oil is old or contaminated it needs replacing:
It is possible to measure if the oil moves well through the engine using an oil pressure gauge. If the pressure is weak, you may have bad seals and need to open the engine.
ATVs with an electric shifter, like the Honda AS models, uses an electric motor to shift through the gears. If the motor does not work, the bike will not shift gears.
The only way to make it shift is by using the emergency shifter (a short-shifting shaft sticking out the left lower side of the engine, use the supplied gear change tool).
If the bike shifts when using the emergency shifter, you need to address the shifter motor.
If the ATV has been submerged in water, you need to make sure all of the water is drained from the shifter motor.
Remove the motor. If the motor does not turn even when hooking it up directly to a battery, it may be burnt out and need replacing.
It is easy to forget that an electric-shift ATV needs electricity to shift. Make sure the battery is properly charged and in good condition.
Related resources:
How to charge an ATV battery
How to troubleshoot an ATV battery that is not charging.
If you try to shift on an electric shift ATV, you may hear the shift motor moving, but it does not shift completely.
You may find that the problem is worse at colder temperatures. Fixing this issue is relatively easy. All you need to do is replace the old gummed-up grease with all-temperature, white lithium grease.
For the complete procedure, go to Hondaatvforums.net
Located on the carburetor, the Honda ES models have an angle sensor that tends to go bad. After replacing the sensor, make sure it is clocked correctly.
When this happens, there is usually no need to worry. In fact, most ATVs are affected by this issue, some more than others.
What happens is that the wheels must be rotated slightly for the gears inside the gearbox to sync (line up).
You may have noticed that this phenomenon gets worse when trying to shift in and out of “park” when standing on a hill.
The best way to avoid this is by applying the parking brake before putting the transmission in “park.” This way, the gears won’t bind up, and you will be able to shift in and out of gear effortlessly.
Previous
Next
This transaction will give LiveWire the freedom to fund new product development and accelerate its go-to-market model. LiveWire will be able to operate as an agile and innovative public company while benefitting from the at-scale manufacturing and distribution capabilities of its strategic partners, Harley-Davidson and KYMCO
$250 discount on all KYMCO products over 300cc
Valid January 1st, 2022 through December 31st, 2022
This includes all active, retired, and honorably discharged personnel from the Armed Forces, Law Enforcement and Firemen.
4.99% INTRODUCTORY OFFER FOR 24 MONTHS
Then 10.99% APR* post rate financing for up to 48 months
(blended APR of 8.38%)
Available on purchases of new KYMCO products between
11/5/2022 – 11/30/2022
6.99% INTRODUCTORY OFFER FOR 24 MONTHS
Then 12.99% APR* post rate financing for up to 48 months
(blended APR of 9.51%)
Available on purchases of new KYMCO products between
11/5/2022 – 11/30/2022
O% for 3 Months APR 2.51%* (Thereafter 33 months at 2.99%)
Available on purchases of 2-wheel products between 5/31/22 to 7/31/22.
Other offers will include an APR of 3.99% for 36 months or 10.99% for 36 months. Participating U.S. Dealers Only.
O% for 6 Months APR 4.56%* (Thereafter 42 months at 5.99%)
Available on purchases of 2-wheel products between 5/31/22 to 7/31/22.
Other offers will include an APR of 6.99% for 48 months or 12.99% for 48 months. Participating U.S. Dealers Only.
3.99% APR For 36 months
Available on 4-wheel products between 5/31/22 to 7/31/22.
Other offers will include an APR of 3.99%, 5.99%, or 11.99%.
Minimum financed $1,500.
6.99% APR For 60 months
Available on 4-wheel products between 5/31/22 to 7/31/22.
Other offers will include an APR of 6.99%, 8.99%, or 13.99% will apply. Minimum financed $5,000.
The ATV clutch is responsible for both gear shifting and vibration reduction during the ride. ATVs for children are no exception.
As a rule, the occurrence of any problems with this component of motor vehicles, the rider feels immediately.
It is recommended to service the ATV clutch every 6000-7000 km, but sometimes all kinds of problems can occur earlier. The rate of wear of the functional components of motor vehicles directly depends on the conditions of its operation.
The following points can serve as a signal that something is wrong with the motorbike clutch:
Depending on the severity of the failure, the problems described above can be solved either by repairing the vehicle's clutch or by replacing it completely. As for Chinese models of ATVs, here it is necessary to check whether the nuts on the clutch are securely fastened. Poor assembly of motorcycles can also cause suspicious sounds in the area of the variator.
To change the clutch on a children's ATV with your own hands, you will need:
In general, this procedure is quite simple and fast. In older models of ATVs, everything is somewhat more complicated. Before proceeding with the dismantling of any components of motor vehicles, be sure to read the instructions from the manufacturer.
Even in Chinese models of ATVs, the clutch boasts an impressive margin of safety, and therefore its breakdown often occurs as a result of improper use of this equipment.
The main causes of premature ATV clutch wear include:
The only way to prolong the life of your ATV clutch is to use it properly and carefully. It is advisable to use good oil, and do not forget about timely maintenance.
The use of high-quality clutch discs in the ATV ensures a smooth start of the vehicle, and also fully ensures reliable grip without slipping even under fairly high loads.
The exception is children's electric ATVs, in which there is simply no clutch disc.
ATV clutch usually needs to be adjusted no more than once a year. Before starting work, place the vehicle on a special footboard.
The process of adjusting the clutch on a motorbike is quite simple, and consists of the following steps:
If it operates too slowly or too quickly, adjust the screw in the desired direction (tighten or loosen). Since adjusting your ATV's clutch is easy, you can repeat this procedure as needed. In the vast majority of motorcycle models, this functional component is adjusted in a similar way. If there are certain nuances in the clutch setting, they are explained in detail in the official vehicle manual.
05/29/2021 3407
Company Kymco has long been known for releasing affordable ATV and UTV models that allow the buyer on a budget to enjoy off-road riding, and the equipment of such machines often exceeds expectations from budget models. The new UXV 450i LE 4x4 2015 is a great example and philosophy manufacturer "more for less".
Let's start from the engine compartment of this new ATV, where there is a strong 443 cc single-cylinder engine with an estimated power of 33 horsepower, using a fuel injection system.
The injection system of these engines guarantees an easy start at any height and excellent throttle response. Kymco produce many different types of engines that are popular, because some other well-known manufacturers use them in their products.
B in the best tradition of Kymco, the new UXV 450i 4x4 2015 is equipped with many accessories, and the price of the machine is very attractive. AT in the best tradition of Kymco, the new UXV 450i 4×4 2015 is equipped with many accessories, and the price of the machine is very attractive.
Transmission the energy of this single-cylinder unit is carried out through a belt CVT transmission and is sent to all four wheels. The driver is free adjust traction by switching between two-wheel drive, all-wheel drive and all-wheel drive mode with differential lock using convenient switch on the dashboard.
What concerns gear shifting (high, low, neutral and reverse stroke), this is done by an easy-to-use lever in the center of the dashboard.
There is only one caveat: to the appearance and / or location of the shift lever need to get used to. It works as it should, of course, but its design and shift direction is different from what we are used to on most machines from other manufacturers.
U instrument panel-mounted shift lever strange the layout and switching order, so the first time you need to get used to it. At instrument panel-mounted shift lever strange the layout and switching order, so the first time you need to get used to it.
Sit the cab of the UXV 450i LE is very comfortable. The ergonomics of the driver's seat is thought out, spacious and simple, starting with the ability to adjust the angle of the steering wheels and ending with a multifunctional digital instrument panel (speedometer, odometer, tachometer, odometer, clock, gear indicator, indicator high beam, fuel gauge, overheat indicator light engine/battery discharge). Everything is set up very conveniently and close to driver.
The only negative is the location of the manual parking lever. brake, which is located directly in front of the driver's left knee. How do we it seems not very comfortable, and you constantly worry that you will touch the lever because of abrupt stop.
Lever parking brake is too close to the driver's left knee, which is not very comfortably. The parking brake lever is too close to the left the driver's knee, which is not very comfortable.
Let's talk a little about luggage compartments, since luggage capacity cannot be taken as due on such machines. Drawers and pouches for stuff on Kymco UXV 450i seem to be everywhere. Firstly, things can be folded under the seats. Two compartments under hood and at the rear of the machine will allow you to take on the road tools, cables and other. The glove box in the cockpit is lockable and can hold a few bottles of water.
Kymco UXV 450i LE 2015 is not deprived of luggage compartments. Kymco UXV 450i LE 2015 not equipped with luggage compartments.
to the suspension of the Kymco UXV 450i LE: the ground clearance of the car is 254 mm, due to which the all-terrain vehicle overcomes obstacles on the way. Independent levers on all four corners provide 190 millimeters of suspension travel, making the UXV The 450i LE climbs over logs, fallen trees and rocks. Even on at low speed, the car confidently and dexterously keeps on narrow paths rough terrain.
Others machine parts like hydraulic disc brakes operate smoothly and without complaints. Dual piston calipers on both front wheels and mounted on shaft, a dual-piston rear brake caliper decelerates predictably and reliably UXV 450i LE.
Thanks With its compact dimensions and small footprint, the UXV 450i LE confidently feels on narrow paths. Due to its compact size and small footprint, the UXV 450i LE feels confident on narrow paths.
UXV 450i is a utility vehicle whose tipping cargo platform withstands up to 200 kilograms.
If you insert the hitch into 2" rear receiver, ATV can tow up to 544 kilograms. It would be interesting to load up the UXV 450i and see how it cope with such a load, but during the test drive we did not have such capabilities. If the sun sets before you finish your work, the combination halogen and LED headlights will light your way. If you need more light, there is additional socket for 12 W.
After test drive it's safe to say that the UXV 450i LE will meet the needs of the average driver, doing everything necessary and keeping passengers in comfort. The model was created with based on the budget car market segment, so that buyers can join the this kind of vehicles without spending a fortune.
ATV equipped with a 443-cube engine, single-cylinder with 33 horsepower, injection. Kymco today produces various types of motors, which are installed on a number of all-terrain vehicles of competing companies.
ATV It has a CVT belt transmission and is sent to all four wheels.
Driver he chooses what he needs at the moment - two-wheel drive or four-wheel drive drive, switching is done by a button conveniently located on the instrument panel panel.
UXV The 450i LE boasts a very comfortable and ergonomic cab. Here everything is like in an expensive foreign car, the steering wheel is adjustable in several positions, the dashboard digital with all indicator lamps as in a car. Here is an indicator gear and mileage counter, low battery light and much more, in in general, there is everything that can help you find out the necessary information about your ATV while riding.
ATV has an impressive luggage compartment. Drawers and compartments that can be shove every little thing in the Kymco UXV 450i everywhere. Under the seats there is impressive boxes, as in long-distance trains. There are two departments under the hood and in the back of the car, where it is convenient to fold tools or cable for towing. The lockable glove compartment in the cab is roomy enough and easily accommodates a couple of water bottles.
High ATV clearance of 254 millimeters allows you to overcome impressive obstacles on the way. Independent arms on all four corners provide 190 millimeters of suspension travel, making the UXV 450i LE climb over logs and stones.
Truck The platform of the UXV 450i ATV is capable of supporting up to 200 kg, and due to body lifting, bulk materials can be transported. If you hook up to an all-terrain vehicle trailer, you can tow up to 544 kilograms of cargo. Looks very stylish a combination of halogen and LED headlights that effectively illuminate the road during the dark hours of the day. If you need more light, there is an additional outlet on 12 W.
Model limited edition Limited Edition with new and original design looks very pretty. The LE package includes alloy wheels, winch with a pulling force of 1360 kilograms and painted plastic. With this model Kymco is also celebrating its 50th anniversary in this market, as indicated by badge on the hood.
Kymco The UXV 450i LE 4x4 is a limited model with an original design that is very looks worthy among competitors of more famous brands. In LE package includes alloy wheels, 1360 drawbar winch kilograms and painted plastic. On the hood of this model flaunts an original badge that announces that Kymco is celebrating its 50 years in the ATV market.
Detail
Model
Type Models: ATV
Make: Kymco
Engine
Type Engine: Single cylinder
Cylinders: 1
Quantity cycles: 4
Power (hp/kW): 33 / 24.6
Cooling: Liquid
Quantity valves: 4
Quantity valves per cylinder: 4
Configuration valves: SOHC
Diameter cylinder (mm.): 89
Stroke piston (mm.): 71.2
Volume Engine (cc): 443
Starter: Electro
Type Fuel: Gasoline
Fuel injector: Yes
Carburetor: No
Transmission
Type: Variator
Drive (front wheels): Shaft
Drive (engine/transmission): Belt
Reverse: Yes
Increased/reduced transmission: Yes
Wheels and tires
Material wheels: Aluminum
C chambered / without chamber: Tubeless
Diameter front tire (inches): 25
diameter rear tire (inches): 25
Width front tire: 8
diameter front wheel: 12
Width rear tire: 10
diameter rear wheel: 12
front tire (full specification): 25 X 8-12
Rear tire (full specification): 25 X 10-12
Brakes
Type front brake: hydraulic disc
type rear brake: hydraulic disc
suspension
type front suspension: Independent double A-arm
Travel front suspension (mm.
): 190.5
Type rear suspension: Independent double A-arm
Travel rear suspension (mm.): 190.5
Rear adjustable damper / preload: Yes
Quantity rear shock absorbers: 2
Rear anti-roll bar: No
Pneumatic adjustment: No
Steering system
Type: Manual
Steering control: Steering wheel
Adjustment steering angle: Standard
Technical Specifications
Length (mm): 2700.528
Width (mm): 1440.2
Height (mm.): 1849.1
Wheeled base (mm.): 1828.8
Radius turn (m.): To be specified
Road Clearance (mm.): 254
Dry weight (kg.): 489.9
Traction force (kg.): 544.3
Capacity tank (l.): 32.2
Volume engine to weight (cc): 0.41
Seats
Type Seats: Bucket
Material: Vinyl
Hinged: No
Headrest: Yes
Quantity places: 2
Quantity rows: 1
Handrail or belt: Standard
Appearance
Frame: Steel
Material body: Plastic
Yes
Protection Headlight: No
Front bumper: Standard
Protection chains: No
Front Mudguards: No
Rear Mudguards: No
Protection gear selector: No
Material cab canopy: Rigid
Frame safety: Standard
Tubular cab frame: Standard
Material cab door: Soft
Camouflage: No
Separator cabin and load platform: Standard
Gauges
Digital dashboard: Standard
Clock: Standard
Tachometer: Standard
Odometer: Standard
Speedometer: Standard
Counter Hours: Standard
Type Temperature Warning: Bulb
Type Fuel level warning: Scale
Model identification
Type (primary): Utility
Minimum driver age: 16
Name: UXV 450i LE 50th Anniversary
Towing and hauling
Size tow bar (in/cm): 2 / 5.
