Alright, ive had my 400ex for about 4 months now and I still can't figure out why it wont shift into 5th. I can't seem to find a new sprocket that actually shifts the gears. Any help is appreciated or links to parts would be great. Thanks!!!
400ex won't shift into 5th
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The sprocket has nothing to do with shifting - my first guess is you are somewhat unfamiliar with motorcycles and ATV's - my second guess is you did not read the owner's manual and my third guess is the quad is not new and actually has a transmission problem.
Are you shifting down from neutral to get first gear and then from first it is 4 up shifts to fifth gear. Are you missing one of these gears? Do you have 2 neutrals? Does the engine just rev in first or fifth position?
A detailed description of what you do and what the quad does would be most helpful.
Are you shifting down from neutral to get first gear and then from first it is 4 up shifts to fifth gear. Are you missing one of these gears? Do you have 2 neutrals? Does the engine just rev in first or fifth position?
A detailed description of what you do and what the quad does would be most helpful.
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Hi, I am interested in knowing what would cause the “no 5th gear” issue. I just rebuilt the engine on my 400ex. That’s the first time I’ve been into one of those engines. I have one down and three up that work perfect. Shifting into 5th gear is like shifting into neutral. Any ideas what I may have screwed up?
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C5 gear is splined to the output shaft - so power transmitted by the mainshaft will result in power transmitted to the rear wheels. Gear C5 is engaged with gear M5 which is freewheeling on the mainshaft - to get power from the mainshaft to the countershaft, gear M3 is coupled to M5 - if there is no coupling of M3 to M5, then it is like being in neutral.
My guess is gear M3 is missing the engagement dogs that couple M3 to M5.
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Those shift forks are not positioned properly
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This was the transmission as I installed it. The dogs were intact. I am wondering if one of the outboard washers may have fallen off while I was installing the shafts. That had happened to me one time rebuilding a TRX 300 FW engine. I was hearing some gear grinding noises so I stopped the engine and open it up found the washer and then reinstalled it and it was fine after that. I hate it but I am going to open it back up this weekend and see if I can find the culprit.
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I believe when I put the forks in that they wound up the right direction. I was just looking at it on my workbench before I installed the transmission. When I actually put the forks in I could read the “left , right and center” stamped on them. They also messed with the shift drum nicely. I will definitely check that though. The first 4 gears work perfectly. 5th is like neutral. I appreciate the feedback. I will check that out when I get back inside the crankcase.
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Meshed. Not messed.
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Did you ever find out why you don’t have 5th gear? Mine is doing the same thing since I rebuilt the engine.
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Either the center or the outside shift forks are inverted - the dowels should al be on the same plane. Just having a thrust washer missing or out of place would not cause loss of a gear, but could lead to gear failure.
The last picture shows the location and direction of installation of the thrust washers and the snap rings.
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The last picture shows the location and direction of installation of the thrust washers and the snap rings.
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Thank you for the diagrams. I will be back inside the engine this weekend.
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