Hello All,
New member here on this forum, but active on a variety of other forums from motorcycles to aircraft.
I purchased an 06 TRX400FA a year or so ago, as a rebuild project. Primarily for hunting purposes, but I won’t turn down a bit of woods running in general when the opportunity presents itself. The engine was running at the time of purchase, but smoked really badly. Fouled the plug in a matter of minutes.
I rebuilt the upper end, installing a new cylinder, piston, rings, wrist pin and all new gaskets from the case top up. Had a local machine shop reseat the valves and I installed new valve seals at the same time. After reassembly, the engine spun over nicely, but wouldn’t so much as pop a single time, unless I shot a tiny bit of starting fluid into the carb inlet. Assuming the carb was probably in foul shape I obtained a complete carb overhaul kit and disassembled, cleaned and rebuilt the carb from top to bottom (It was horrendously filthy, and the CV slide was frozen in place. It did sit for most of a year before I started working on it). I also removed the complete airbox system and thoroughly cleaned the mud, dirt & crud from all that and the ducting, finally reassembling everything and adjusting all the linkages.
The engine now cranks and runs fine, idling well on the choke till it warms up. After I shift the tranny into drive, and begin riding around my shop area a bit, I noticed the very first time I cranked it up and rode it around after the rebuild, I could get it to occasionally shift to 2nd and 3rd, but it took a tremendous amount of button clicking and selecting back and forth between ESP & Auto. On the second and subsequent runs, I notice that it will not shift above 1st gear, regardless of what I do with the shift buttons, and regardless of whether I select ESP or Auto.
Admitted, the last ATV I owned and operated for any length of time was an old Suzuki 125 three-wheeler, but I’m thinking it ought not be this difficult.
Any assistance appreciated 🙂
New member here on this forum, but active on a variety of other forums from motorcycles to aircraft.
I purchased an 06 TRX400FA a year or so ago, as a rebuild project. Primarily for hunting purposes, but I won’t turn down a bit of woods running in general when the opportunity presents itself. The engine was running at the time of purchase, but smoked really badly. Fouled the plug in a matter of minutes.
I rebuilt the upper end, installing a new cylinder, piston, rings, wrist pin and all new gaskets from the case top up. Had a local machine shop reseat the valves and I installed new valve seals at the same time. After reassembly, the engine spun over nicely, but wouldn’t so much as pop a single time, unless I shot a tiny bit of starting fluid into the carb inlet. Assuming the carb was probably in foul shape I obtained a complete carb overhaul kit and disassembled, cleaned and rebuilt the carb from top to bottom (It was horrendously filthy, and the CV slide was frozen in place. It did sit for most of a year before I started working on it). I also removed the complete airbox system and thoroughly cleaned the mud, dirt & crud from all that and the ducting, finally reassembling everything and adjusting all the linkages.
The engine now cranks and runs fine, idling well on the choke till it warms up. After I shift the tranny into drive, and begin riding around my shop area a bit, I noticed the very first time I cranked it up and rode it around after the rebuild, I could get it to occasionally shift to 2nd and 3rd, but it took a tremendous amount of button clicking and selecting back and forth between ESP & Auto. On the second and subsequent runs, I notice that it will not shift above 1st gear, regardless of what I do with the shift buttons, and regardless of whether I select ESP or Auto.
Admitted, the last ATV I owned and operated for any length of time was an old Suzuki 125 three-wheeler, but I’m thinking it ought not be this difficult.
Any assistance appreciated 🙂
*** After posting this, I found the Sticky on the shift motor gear grease cleaning and re-lubing (I had searched for this exact problem in the forum before my post, but nothing showed). I will go thru that procedure before I do anything else with it. Still welcome any other feedback and info.
D.D.
