So I have this barn find Honda ATC 250es Big Red. Cleaning up fuel system, new carb, fresh fluids and air filter resulted in easy start and a well running engine. However, it was hard to shift through the first few gears. It would shift, but “clunk”. Scary.
Motorcycle mechanic suggested that since it had been sitting for 5 years, to try while riding around “feathering” the shifter to rough up the clutch friction plates. That felt like it helped a little but certainly not enough. Next he suggested replacing the clutch friction plates. I did and also replaced the one way bearing in the centrifugal clutch and put on new cer clips. Not finding an appropriate clutch puller I used an air impact to disassemble and reassemble, thusly torquing was by guess. Filled with appropriate ATV oil for wet clutches, adjusted the external clutch adjustment screw on the side of the case per manual directions then ready for test drive. First impression when I pulled up the shifter from neutral to 1st gear it lurched forward and died. Subsequent attempts same results. Noted that if after I pulled up on the shifter to get it in gear, and I slowly lowered it back down, it would roll forward and not die. After that, the shifting through up and down gears easy cheesy and no “clunk” like my original problem.
I rode it around today for about an hour shifting up and down, stopping, starting using my slow feathering of the shifter from neutral to 1st gear. However it never improved and still wanted to lurch from neutral to 1st. But again, at least no "clunk" sound.
Soooo this very green rookie three wheeler mechanic is looking to you folks for insights and possible suggestions on where I go from here.
Thanks!!!!!!!!!!!!! =)
-Jon