The tear down

I got home tonight and decided to start tearing down the quad to make it easier to work on. I started with the racks and the front guard. I noticed it had been damaged fairly bad in a collision and could probably not be repaired easily. I was able to find a good used replacement on ebay for $35 with shipping and so I purchased it as a replacement. After all the racks were off I uninstalled the rear fenders. This gave me good access to the left hand side of the engine where the clutch and shifting mechanism is located. I drained the oil and pulled the left cover. I removed the clutches and started inspecting the shift rod and cam. I did not see any physical damage but while manipulating the gear I noticed I could shift out on neutral into first and second gear. I could shift back into first gear but not back to neutral with out a lot of messing around, and could never get the quad into third gear at all. This has lead me to believe that either the shift forks are damaged or the shift cam grooves are damaged. Not the best news considering it means I will have to split the case to get at the damaged equipment.I pulled the front fenders, which meant pulling the handlebars and unhooked all the cables and tubes from the engine and carburetor. I removed all the mounting bolts and with a little muscle I was able to pull the motor and get it onto the bench.

I am again impressed with how well this quad is put together. Everything is heavy duty and well thought out. Although the frame is dirty the powder coat has protected the metal very well.