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rjh
02-17-2005, 12:44 PM
I have a 1985 ATC250ES Big Red that is stuck in gear. The shifter lever is free and moves fine. But the trans. is stuck in gear. Any ideas of how to get it out of gear. I have a service manual and have taken off the right crankcase cover in search of a problem. It appears the reverse shift is in the reverse position and it will not move. Any ideas for me?
bigredhead
02-17-2005, 02:47 PM
I'd start with following the reverse cable.. make sure it's not seized and not returning.

Then check the clutch mechanism springs, etc..

Got any pictures ?
rjh
02-17-2005, 03:44 PM
The reverse cable is free. Actually I disconnected it to take the cover off. That all works smoothly. My next step is the external shifting mechanism unless someone can point me in another direction.

Sorry no pictures.
Howdy
02-17-2005, 04:15 PM
The reverse cable is free. Actually I disconnected it to take the cover off. That all works smoothly. My next step is the external shifting mechanism unless someone can point me in another direction.

Sorry no pictures.

Your problem is probably located under the left side cover. I have 3 common problems marked in the picture that I attatched.

Item #6: I have seen where this breaks.
Item #8: I have seen this item break or become loose.
Item #21: I have seen this one come loose.


Of alll the machines I have worked on this machine is probably the easiest to fix a shifting problem ( as long as it isn't a shifter fork / tumbler problem ).
Howdy
rjh
02-17-2005, 04:30 PM
Thanks for the ideas Howdy,
I will tackle that side of the case tonight.
bigredhead
02-17-2005, 04:32 PM
8 and 21 i replaced not long ago myself.. along with 31 ( 31 had some play in it making the shifting sloppy ).

The manual says you can remove the left side cover with the engine in the frame, but be aware that a 20 year old machine with moderate use will need the motor mounts loosened up ..

IF you get into this, before you open it up, get both the case and starter reduction gear gaskets, as well as a new oil seal for the shifter.
rjh
02-17-2005, 04:35 PM
Do you know if those seals and gaskets are still available thourhg Honda?
bigredhead
02-17-2005, 04:38 PM
yes they are... 10 and 6 $ ish.
bigredhead
02-17-2005, 04:41 PM
http://www.3wheelerworldforums.com/showthread.php?t=30576&page=1&highlight=urgent

read this for reference.
rjh
02-17-2005, 05:05 PM
Good reading. I had the same problem getting the rightside cover off. It just took a while but it eventually came of with some pounding and prying. Thanks
rjh
02-18-2005, 10:01 AM
I found the problem last night. The gearshift arm was broken and laying in the case.

Thanks for all of the help. I'm sure I will need it again.
kdagenais
02-18-2005, 01:17 PM
Just wanted to refer you to the cheapest place to get Honda parts and it is Servicehonda.com. Get the part numbers from partsfish.com and go to service honda to order them. I just ordered a ignition coil from them and saved $30.00 from partsfish & dealer for that matter. Anyways just a FYI for you to research if you would like.