Shifting problems ATC200E

[Tanner]

I have built a go kart and used a honda ATC200e engine which as far as i know has a five speed automatic clutch transmission. It runs great and i can get it up to fourth gear but no matter how fast or how high i get the revs it never shifts into fifth. I have deliberately counted the amount of times it shifts and it will only go to fourth. Any tips or tricks would be helpful thank you

[tri again]

Interesting.
Gotta warn you that Everyone will want to see pictures.

so it shifts very normally 4 times but no 5th?
Can you get the search key to work?
The front page of 3ww should also have original sales brochures
Maybe it only had 4 fwd gears? idk.

can you click on:
service manual

Nice work and welcome to 3ww

[my1423]

People mod go karts in all sorts of ways.
Could be they regeared it and removed one along the way. Or prevented, or skipped, ect
There is a little indicator shaft by the pull starter that originally had a little white red tipped indicator on it.
This was to point to n for starting. It attaches directly to the shift drum!
Downshift all the way to neutral.
Make mark on the case and shaft if missing the pointer.
Shift to 1, make a mark, then repeat for all gears.
See if the drum is stopping from going into 5th, or it is skipping a gear.
Should have even marks in a circle for all gears.

[kb0nly]

Well its going to be a five speed for sure, and after reading your post you built it correct? So there is little chance someone else modified the trans in the motor for some reason.

Does it shift smoothly from first to fourth? Its not really speed depended either, you don't have to be going x amount of mph to get into fifth gear, its not speed dependent, it just takes engine rpm for the clutch to engine at whatever gear you select. You can take off in any gear you wanted for example, but obviously the lowest gear gives the most torque for takeoff just like a manual trans car.

My guess, shift stopper or shift fork issue. I would remove the right cover, drain the oil first, and then shift it from neutral through all the gears, not running of course, so you can see if the shift drum advances, and if not then you have to go digging to find out why, just hope you dont have to split the case.

my1423 made a very good suggestion using the neutral indicator to check the shifting as well, thats a good place to start.

[Tanner]

So here are some picture of the engine and the buggy it self also to shift indicator as you can see it goes all the way up to fifth gear while it is NOT running. Should i go looking for a reason why it wont do it while its running?

[DennisJJ]

Thanks Tanner for the pic of the "neutral indicator".....I had to replace my recoil spring, and seen this weird extra bolt.....I found out that it was the spot for an indicator, but had absolutely no idea what one looked like......I'll whittle something out, and mark it off. Pics are so great.