Is one of my Gears gone??? :(

fish22 · Sep 26, 2009

???Hey guys im building an older ('90) Warrior Took her out for a spin today, and she ran pretty good for her first time out.
I know how to make an engine run and tune a carb, but beyond that im kinda lost....

Problem:
When i ride it, 1st & 2nd gear are ok, but when you get to 3rd it acts really weird, it will barely go then not go, then barely hook up then not hook up. BUT 4th gear is fine. I got it up pretty quit in 2nd, then went straight to 4th and all was well. (I never made it beyond 4th cuz i dont have enough lawn, its only an acre). In third every is going normal, but its like its not "catching" whatever it needs to to make the quad go forward.

So is that gear gone or shot or what?
Is it the gay shifting setup(horrible)?

If that gear is gone, how do you go about fixing it.....
Thanks guys.

She has an FMF, and has been bored(dont know how much). K&N.

yamarider · Sep 26, 2009

It's something damaged internally, there's not really a way to say what it is until you tear it apart and look for the damage. Could be a broken gear, bent shift fork, or a number of other things.

Guest · Sep 26, 2009

most likely a bent shift fory... it's pretty common in second and third gear to bend a shift fork if you dont know how to shift w/o clutching.
but as said you wont know until you tear it down

your going to have to pull the motor, pull head and jug off the bottom end and split the tranny case.
(while head is off look on top of the piston for the stamped numbers to tell you how much over it's been bored.
as for fixing the best thing you can do is get a clymer manual.

fish22 · Sep 26, 2009

man.....
that sucks.
where do i get the stuff to do that crap?
Can i just do it in my shop or do i have to get someone special to do it?

Guest · Sep 27, 2009

you can do it if your comfortable with splitting the tranny case... like i said as long as your smart and get a clymer manual you'll do fine.

and as said chances are it's as simple as a shift fork and those are no trouble at all to change

lets see you'll need a philips screw driver, a flat head screw driver, a few wrenches, just the common tools.

i would suggest taking all screws out that hold the two case halfs together and laying the tranny over on the clutch side so all the gear spindles stay in that half the tranny

Guest · Sep 28, 2009

hey dude.
I've got to start pulling a engine off a warrior for a dude tomorrow (i'm a motorcycle mechanic) it needs main bearings and i'll try and make a video log on it for you and show you how to tear one down and show you the shift fork and stuff

fish22 · Sep 28, 2009

Man that would be so awesome. Im not scared anymore after everyone telling me its not too bad, but a video would be so cool. I was gonna start pulling it out tonight. (hopefully, college, work, etc)