How to make shift cable for atv


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ATV Won’t Go Into Gear or Shift – the Most Common Causes

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

Step 1: Does the ATV shift gears as normal with the engine off?

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.

Step 2: The idle is set too high – causing the clutch to engage

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.

Step 3: The CVT is engaging too soon or not disengaging properly

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.

Cause 1: The clutches are dirty

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.

Cause 2: The clutch spring is getting weak

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.

Cause 3: The clutches are not aligned; a bad or loose engine mount

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.

Cause 4: The clutches are not aligned; the belt is offset (common issue)

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.

Cause 5: Worn drive belt

If the drive belt is worn too much, it will ride low on the sheaves, causing a slight creep.

Cause 6: Using an aftermarket drive belt

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.

Cause 7: Shredded drive belt

Remove the belt cover. If the belt is shredded, it may have gotten wrapped around the driven shaft, causing it to bind up.

Cause 8: Worn EBS washers (common issue)

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.

Cause 9: Bad one-way bearing

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.

Step 4: The ATV won’t shift gears even when the engine is turned off

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. 

Cause 1: Gear linkage is worn or out of adjustment

Some ATVs have adjustable gear linkage. If not adjusted correctly, the bike will not shift as it should.

How to inspect and adjust the gear linkage:

  • Make sure the ATV is in neutral.
  • Remove the linkage from the shift box.
  • Inspect the bellcranks to make sure they are not stripped or have split.
  • Inspect the ball-ends for wear.
  • Replace any damaged components.
  • Set the gear shifter to neutral.
  • Adjust the ball ends until they drop straight onto the shifter.

Cause 2: Manual clutch transmission issues

On ATVs that has manual clutch transmissions, you should make sure that:

  • The handlebar-mounted lever is not damaged.
  • The cable is not broken.
  • The cable does not need adjusting.

Cause 3: Internal gearbox issues

To test your gearbox for internal damage without splitting the case you can try this method:

  • The engine should be off.
  • Remove the belt cover.
  • Remove the drive belt.
  • Shift the bike into gear.
  • Try manually rotating the primary clutch; the bike should move.
  • If the bike does not move, you likely have an issue inside the gearbox.

Cause 4: Wore or bent shift fork

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.

Step 5: Wet clutch or hydrostatic transmission issues 

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.

Cause 1: The oil level is low

Make sure the oil level is correct or the bike may not shift as it should.  

Cause 2: The oil needs replacing

If the oil is old or contaminated it needs replacing:

  • Drain the old oil into a drain pan.
  • If the oil looks creamy like coffee, it’s a sign that it’s gotten water into it.
  • If the oil is black and smelly, it’s old and long overdue for replacing. 
  • Also, look for debris such as old seals being drained out with the oil.
  • Add new oil to the correct level. Make sure it is according to spec. 
  • Let the bike run for 10 minutes.
  • Change the oil once more.
  • This final time, also change the oil filter. 

Cause 3: The oil is not moving correctly through the engine

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.

Step 6: Honda ES electric shift transmissions: shifter motor issues

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. 

Cause 1: The motor is wet

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 and give it a proper cleanse with an electric-cleaner. 
  • Let it dry and re-grease it with dielectric grease. 
  • Hook up the motor to a 12V battery to test it before reinstalling.
  • Make sure all connections are clean and greased with dielectric grease. 

Cause 2: The motor is burnt out

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. 

Cause 3: The battery is not adequately charged

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. 

Cause 4: Too heavy or gummed up grease in the shift motor gears

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

Cause 5: Bad angle sensor

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.

Step 7: The ATV won’t shift into gear or into neutral without rocking it back and forth

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.

ATV winch use

A winch is a must have for off-road riding. It allows you to pull a stuck ATV out of mud, water or deep ruts. Many models of CFMOTO ATVs and ATVs have a winch from the factory, for others it needs to be purchased separately. In this article, we will tell you how the winch works, what to look for when choosing, and also give useful tips on how to use it.

How the winch works

ATV winch is a drum with a cable. An electric motor is located on one side of the drum, and a gearbox on the other. Rotation from the electric motor to the gearbox transmits a shaft that passes inside the drum. The gears of the planetary mechanism are located in the gearbox.

Reducer reduces speed and increases traction. The rotation from the gearbox is transmitted to the drum, which winds the cable, creating traction and gradually pulling out the stuck equipment.

What is traction

One of the key parameters to consider when choosing a winch is traction. It determines the maximum weight of the load that can be torn off the surface. With each skein of the drum, the winch force decreases.

Thrust is measured in pounds (labeled on winches as lbs), 1 lb = 0.45 kg. The force depends on a number of features: the diameter of the drum, the number of wound turns, the power of the electric motor, as well as the gear ratio of the gearbox.

It is not always necessary to choose the most powerful and fastest winch: the more powerful the mechanism, the more difficult it is to handle. Beginners can harm equipment and even their health - it is not uncommon for a broken cable or a broken hook to cause injury.

What to look for when choosing

Power

Matches the cubic capacity of the ATV:

  • up to 400 cubic meters - a 2000 lbs winch will do;
  • 500-600cc - 2500-3000lbs
  • 700-800 cubic meters - at least 2500, and better - 3000-3500 lbs;
  • "liter" ATV or SSV - from 3000 lbs.
Rope material

Steel - cheap and easy. Requires work with gloves, not repairable. May cause injury if mishandled.

Synthetic - requires maintenance but is easy to use. It does not "shoot", and if the cable is damaged or torn, it can be braided on the spot.

Most experts believe that material choice should be based on personal preference: some riders lean towards steel over time, others towards synthetics.

Installation and connection

The winch is installed on a special platform on the ATV frame. If there is no platform, you need to buy it and install it according to the instructions. The site has standard anchor points that fit classic winches up to 3,500 feet of pull.

When choosing a winch, pay attention to the width of the drum:

  • models up to 3500 feet of pull have a narrow drum and fit standard fasteners;
  • 4500+ ft. thrust models have a wide drum and require field modifications to fit;
  • models with 4000ft thrust can have a narrow or wide drum - you need to look at the fact.

With certain skills, you can modify the fasteners and install almost any winch - the main thing is not to make the fasteners “to break” and not to strengthen weak points. If the ATV is under warranty, it is advisable not to touch the frame and buy a regular winch.

Installing the winch is easy, but the connection will have to be tricky. To lay the wiring, it is advisable to remove the plastic from the ATV. The winch must be connected to the control unit and battery. It is recommended to keep the power cable as short as possible to avoid current loss. All wires must be hidden in the corrugation so that they do not come into contact with the frame and are protected from moisture.

How to winch the ATV out of mud

  1. Wear gloves. A steel cable can severely injure hands, and calluses appear when working with a synthetic belt.
  2. Switch the lock to manual unwind. This will allow you to manually unwind the cable, saving time and battery life.
  3. Loosen the hook and put a webbing strap on it.
  4. Unwind the rope to the required length. Make sure the cable is tight.
  5. Wrap the bark strap around a tree or drape it over the tow bar of another machine. The attachment point should be as far away as possible - this will create a larger shoulder and increase traction.
  6. Attach the ends of the sling to the hook.
  7. Switch the locking lever from manual unwinding.
  8. Tension the cable gently.
  9. Inspect the fulcrum and check that the cable is properly routed. It is important to make sure that everything is securely fastened and works properly.
  10. Remove all obstacles from the path. The cable must lie flat on the drum.
  11. Slowly tighten the cable and apply gas. It is important to stick to the intended trajectory.
  12. After the ATV is able to continue under its own power, wind up the rope.

Tips and Tricks

  • Wear gloves when handling the winch to protect against cuts and scrapes.
  • Get a cable block to increase traction. This is especially true when running in difficult situations.
  • Keep track of the battery charge so that it does not run out at the most crucial moment.
  • Pull out the equipment intermittently, turn the steering wheel towards the cable - this will facilitate the work of the electric motor.
  • Do not hold on to or lean on the cable as this could result in injury.

If you have any questions or would like further advice on purchasing, installing, operating and maintaining an ATV or ATV winch, please contact your nearest authorized CFMOTO dealer.

Dealers CFMOTO

How to change gears on an ATV - ATVARMOR

Articles

  • Published bakkie

02 Dec

Any wheeled vehicle - from a bicycle to a multi-ton truck - has a transmission in its device: a system that transmits rotation from the engine to the wheels. The operation of the transmission - and therefore the speed of driving - can be controlled by shifting gears.

Gear shifting is organized differently in each mode of transport. In the article below, we will tell you exactly how to shift gears on ATVs, and what gearboxes are found on such equipment.

Types of gearboxes for ATVs and a list of gears in them

Gearboxes for ATVs can be of two types:

  1. Mechanical. Similar to motorcycle gearboxes. They are put mainly on racing models, but in recent years they have also begun to be found on utility ATVs. They have a foot clutch or clutch with a lever on the steering wheel (in most cases it is), and a foot shifter. Manual transmission usually has 4 “forward” gears, neutral and reverse.
  2. CVT. They have high and low (L and H) forward gears, neutral, reverse and parking brake. Some ATVs (the cheapest and least powerful) can have only one forward gear. You don't need to depress the clutch to shift.

Rare and mostly found in older models, but other variations can be found. For example - "automatic" with the ability to manually shift gears.

Manual ATVs are a little more difficult to drive (at least at first, until you get used to it), but you can more accurately select the appropriate mode. And vice versa: CVT "boxes" are much easier to operate, they are easy to master for a beginner who gets behind the wheel of an ATV for the first time. But on the other hand, with active driving along a route with variable difficulty, riding a CVT will be a little less convenient.

For example: you are driving on a flat packed dirt road on H and you see a large stretch of muddy road ahead with deep mud (or a steep hill, or bumps, or stones). You will have to come to a complete stop and shift to L, drive through mud, and when you get back on a dry road, come to a complete stop again and shift back to H. , like motorcycles, and a manual clutch lever on the handlebar on the left.

The foot lever device can be of two types:

  1. One lever. Gear shifting is carried out with the toe of the foot, pressing the lever from top to bottom (gears from 1 and above) or from bottom to top - from a higher gear to a lower one.
  2. Two levers. Gear shifting is carried out by the heel and toe of the left foot. The rear lever shifts gears up, the front lever shifts down.

The shift itself is carried out in the same way as on motorcycles:

  1. We start the ATV (always in neutral or park gear).
  2. Fully depress the clutch.
  3. Press the gear lever with your foot, selecting the first gear.
  4. Slightly press down on the gas trigger and at the same time slowly release the clutch lever. When learning on any type of transport with a manual transmission (car, motorcycle, truck), this point is the most difficult, and it can only be gained by practice, catching the balance in working with the clutch and gas. If you have experience driving any vehicle with a manual transmission, you will quickly get used to an ATV with such a gearbox.
  5. Having completely released the clutch, we move only with the help of gas, adding or decreasing it (and, if necessary, braking with a foot or hand brake).
  6. Having gained speed, we squeeze the clutch again, and turn on the next gear with our foot.
  7. Press the gas trigger and slowly release the clutch.
  8. Repeat steps 6-7 for further upshifts.
  9. If the gear needs to be reduced, we act in the same order: we squeeze the clutch, and press the gearshift lever with our foot to reduce the gear.

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