Honda ATC 200S goes only into first but wont move

[DigitalDwarf]

So, I was out at Silver Lake State Park Sand Dunes enjoying a nice brisk morning. I was climbing all of the hills (sometimes having to down shift on the fly). I stopped my trike on a flat area and put it into neutral. I then put the bike into first gear and the bike wouldn't move. It revved up and the wheels sometimes wanted to move partly, but it wouldn't move.

I had to put the trike into neutral and push it out.

Now here is the dilemma:

Bike will shift into neutral and first, but when i try to shift into the other gears, the pedal will go down but the shift indicator does not spin indicating a shift.

I took the panel off to look and the clutch and gears and one of the bolts unloosened itself and is now bent. See pics...

My question is would this cause the bike not to shift? i can see why it wouldn't move because of the bolt. Also where do I get a bolt to replace it?

Thanks

Caleb

Please see attachments for photos of problem

Well actually having a hard time getting pics to load :confused:

[tri again]

yupp, no pics for me but shift trouble is common these days.

I think the common 'shift drum stopper' or whatever it's called
either comes loose or bends or breaks but are available
locally or mail order for under 10 bucks.

That's MY next project too.

Manuals are free in the 'world class help' section btw.
A metric bolt should be avail anywhere. Local HW store, auto parts.
Check the grading on it aka
grade 3 or 5 or 8 or whatever indicated the hardness.

also it you can't find the exact size, get one a little longer,
'spin a nut on it,
cut off the bolt and then take the nut off.

It will preserve the threads.

[DigitalDwarf]

So I fixed the bolt in the pressure plate, and reassembled appropriately, but now the bike will not shift into gear and engage. I am able to put the trike into first gear, but when I throttle up it will not moved (like the clutch isn't engaging. Any ideas why this might be?131787131787

[tri again]

Hi again.
The pix should get you some good advice.
Did you find the free manuals?
Did it look like that bolt coming out hit anything important?
Seems like it would almost need a reason to bend but hopefully didn't hurt anything else.

Have you tried a regular ol' clutch adjustment?
Any interesting chunks in the 'oil pan" / bottom of the case?

[DigitalDwarf]

Hey, thanks for the reply. I did find the manuals, which is how I learned to take the case apart, etc.

Yeah, I tried to the clutch adjustment. I screwed it all the way counter clockwise then loosened it a 1/4 turn. The shifter pedal was almost to stiff to shift into gear at this adjustment, but I was still able to get into first by pressing down extremely hard. When in first it wouldn't move. I tried to loosened the screw clockwise at more intervals and it still wouldn't engage the clutch.

I think the pressure plate bolt bent when it hit the centrifugal clutch (see pic). Both clutches spin by hand, if that makes a difference. I didn't find much at the bottoms of the case except two or three small metal shavings.

Any ideas?

[tri again]

Nice pix, btw.

I JUST opened my first clutch job so never really had one apart all the way yet.

But you say it worked perfectly until it wouldn't shift?
Could that bolt have 'warped' or bent the drum/bell looking thing?
Doesn't even look like they touched.

[DigitalDwarf]

Bump. Really at a loss here....

[tri again]

Bump. Really at a loss here....

Man, I wish I knew what to tell you.

I'm gonna try a tear into mine today and may come up with some ideas.
I wonder why no one else has jumped in.
If nothing else, they'll usually make fun of my suggestions, at Least!

Have you tried the search key?
something like
"shift problem" may pop up a hundred entries from the last few years.

so now what?
everything looks good after the bent bolt got replaced.
you adjusted the clutch and no change.
you put it into first gear, it clunks in like it really IS in first, give it gas an nothing happens, as in, it doesn't go forward?

Surely you know that if you move the shifter into a gear and let off the shifter slowly, it's
almost like slipping a manual clutch?

Have you tried wiggling the shifter up and down and / or try starting out in 2nd or 3rd?

[thestud25]

From the Picture it looks as if the plate is bent. Will it shift through the gears with the trike off? If not, you have more than likely broken a shift fork. Were there any metal chunks or shavings when you pulled the side cover?

[DigitalDwarf]

With the bike off, I am still unable to shift into all of the gears. If I tighten the clutch adjustment to max I can shift into all of the gears. Also if I rock it back in forth while trying to shift it seems to go into the gears. I only found a couple small shaving at the bottom of the case, which I just attributed to the bolt, but it might have been something else. Do I need to tear the case apart to get to the forks? Thanks for the reply guys.

[thestud25]

To me it sounds like your clutch and or friction plates are shot and need to be replaced. To get to the shift fork follow the shift shaft back. I am not positive on this model if you need to split the case.

[atc007]

If the bike shifts while off,but not on. And you are getting the gears. It's most likely in your clutch. Yes,,your tranny and ALL of it's parts are in the cases. Requiring pulling,and splitting. I'm busy here and should have studied your post,,but did not. If that bolt was like that when you opened it up,,it appears it worked loose,,. Didn't it tear anything else up??

[Howdy]

Check the shifter arm ( migh be broken / bent ) behind the 2nd ( manual ) clutch. To access it you need to remove both clutches. You will need a spanner wrench to remove the clutches.

[zackwhite]

make sure u got the clutch tighten up to the right speck