Hi/Low gears

[TrailerRider]

Ok had issues with our 85' 90 where it had issues staying in hi/low. It has been sitting awhile so today I decided to check clutch adjustment and/or swap hi/low gears from another 85' 90. I tried to adjust the clutch according to the manual. That didn't go so well because I had to mess with the adjustment to get it to release and go back into gears lol. After I read the manual and reassembled the gears I cannot get the chain sprocket to move freely with gear in neutral. If I remove the gears from high/low it spins freely. I can switch from high to low in neutral but regardless the drive sprocket will not turn freely. I can use a wrench to turn it but its obviously its not right. I have all the gears installed correctly I believe. All went together and hi/low housing bolts up fine. I added some assembly lube to the gears as well before I bolted the case back on.

So my question is how do you set the clutch adjustment for say a new clutch? Also if the clutch is correct or close and it nuertal what could cause the drive sprocket to not turn but turn fine if the hi/low gears are removed?

[TrailerRider]

I read the manual again today and still cannot wrap my mind around how with the hi/low gears in place won't allow the drive sprocket to turn. Is there a way to eliminate the hi/low gears and run similar to a 185?

[Gearheadtom]

Does the output shaft of the motor turn fine with the high/low gears out?
All the clutch adjustment does is adjusts the free-play between the shifter linkage and the clutch. The more you turn the screw in the looser it gets, and the sloppier the shifter gets. Turn the screw out until you feel resistance (clutch linkage hitting the clutch), then back in a bit to set the proper free-play.

[effort=results]

Take high low cover of and inspect. Also rock the wheeler back and forth while u try to put it in from hi to low.

[TrailerRider]

ok I finally had a chance to go out and take the cover back off and took pics and a video. The shaft turns freely as you will see in the video. The only thing I can figure is I must be putting the gears in wrong. See the attached pics of the gears in cover and motor.






Video:
https://youtu.be/36jn6JzeBoo

[TrailerRider]

ok update I was messing with it again this morning, tore everything back out and rechecked everything and slid chain on while sprocket was loose, slid cover on before I tightened the screw down and it spins freely. I tightened the screws down and now it won't turn again. I loosen them all up and pull cover back and it spins. I slide over back on and tighten cover and no spinning. If I loosen the screws but leave cover on it spins. As soon as I tighten a screw something binds up. I must be missing a shim or something but I cannot see where. Anyone have a diagram of how everything goes back together or maybe let me know if I am indeed missing a shim or something?

[86125m]

Are you missing a gasket or a washer somewhere because just a millimeter off of where its supposed to be and everything goes to heck some times. These motors are pretty sensitive.