AC 400 shifter problem? - ATVConnection.com ATV Enthusiast Community

sassee · #1 (**permalink**) 10-04-2009, 07:56 PM

Help! My son informs me this afternoon that the AC won't shift gears. He was riding and it would no longer shift. I looked at it briefly and the heal/toe shifter moves, but it's not shifting into any gear "normally". If you really hit the heal hard, it'll shift into 1st and drive off normally. Hit it really hard again and it'll go into second but you basically have to stomp on it. It downshifts back to neutral normally with the toe. This is a 2001/2002 (??? I forgot) AC 400 2x4 Green. Any suggestions?

sassee · #2 (**permalink**) 10-06-2009, 10:14 AM

Any thoughts? anybody?

swampyjunior · #3 (**permalink**) 10-06-2009, 06:33 PM

Try adjusting the clutch since it is a manual shift. May be that it has backed off the adjustment a little. Lots of times when my machine slips in gear or gets hard to shift the clutch needs adjusting and it clears right up. May need to do it once or twice if it is way out of adjustment.

SJ

sassee · #4 (**permalink**) 10-07-2009, 08:53 AM

how do you adjust the clutch? It had gotten increasingly harder to shift over the past couple years.

ernie

swampyjunior · #5 (**permalink**) 10-12-2009, 01:12 AM

Below are the steps I use to adjust my clutch. I have had to do this about every other year. Give it a try.

1) locate the clutch adjustment cover. It is an oval shaped cover located on the same side as the shifter.

2) Using an impact driver or large screw driver remove the two screws securing the clutch adjustment cover. Account for the O-ring gasket which usually sticks to the cover.

3) Loosen the jam nuts securing adjustment screw #1 (forward) and screw #2 (rearward).

4) Rotate screw #1 (forward) screw counterclockwise until it stops. It may turn very hard and click.

5) Rotate adjustment screw #2 (rearward) alternately clockwise and counterclockwise to ensure free movement without binding; then lock the jam nut securing adjustment screw #2.

6) Rotate adjustment screw #1 clockwise 1/8 turn then lock its jam nut.

At this point test drive to see if shifts OK. You may need to repeat these steps a couple times to get it adjusted if it is way out.

7) reinstall cover and tighten screws. I also put a little clean oil on the O-ring with my finger before installing it.

Hope this helps and sorry I don't have pictures for you to go with this.

Swampy

Niles · #6 (**permalink**) 10-13-2009, 02:09 PM

I had a similar problem on my 02 300. It wasn't a clutch adjustment. I just had to adjust the hind joint so the lever would have a little more play. I too have heel toe shift and that fixed it.