Its SUPER HARD to change gear

This is a discussion on Its SUPER HARD to change gear within the Repair and Maintenance forums, part of the Suzuki ATV Technical Discussions category; Hey all! I am having problems with my '03 Vinson 500. Earlier today I was fine when I changed gear ( 1,2,3,4,5). I was driving ...

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Old 01-04-2011, 08:22 PM   #1
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Its SUPER HARD to change gear

Hey all! I am having problems with my '03 Vinson 500. Earlier today I was fine when I changed gear ( 1,2,3,4,5). I was driving thru 7 inches of snow, so that shouldn't be a problem. I'm new when it come to ATV's so help if you can! We always have a good amount of oil in it, so that shouldn't be the problem. What happened is that out of no where, it was nearly impossible to shift. I couldn't do it with my foot. I have to bend over and jerk it up and down repetativly for it to go one gear up or down. Has this happened to any of you before? I can still run the atv, and the engine sounds great , so no prob there. The reason I am asking here is that it's a 4 hour drive to the nearest atv store that is willing to try to fix it. We have a neighbor who is experience with parts and installing them, but he's never heard of this happening before so I am asking here. Any help would be greatly appreciated.
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Old 01-04-2011, 08:25 PM   #2
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What kind of oil you using,is the clutch slipping.The clutch may only need to be adjusted.
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Old 01-04-2011, 08:28 PM   #3
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10W40 like it says on my 4 wheeler. How would I adjust the clutch?
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Old 01-04-2011, 08:31 PM   #4
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Are you using a oil that has the wet clutch additive,or just regular motor oil.there is a adjustment on the right engine side case.
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Old 01-04-2011, 08:35 PM   #5
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I'll have to check on the bottle, my husband had gone out to buy it and put the oil in the atv so I don't know. Cause we lifted up the atv by the winch and looked at the bottom, nothings broken. But when I look on the right side of the engine side case what am I looking for?

Sorry.. I'm a newbie.haha
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Old 01-04-2011, 08:40 PM   #6
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Vinson Clutch adjustment

Pull off the cover on the right hand side, that's held on by 2 phillips screws.
Loosen both nuts, ones a 10mm the other is 14mm
Turn the screw with the 14mm nut with a flat head screwdriver counter clockwise till it stops.
Now tighten the 10mm nut.
Now turn the screw clockwise 1/4 of a turn.
Hold the screw and tighten the 14mm nut.

To see if it worked, start the quad, shift it into first but hold the shifter up with your foot and rev the engine.
It shouldn't move at all.
Then when you put it in gear it should go normal.
That means it good to go.

Be sure you are using a oil that is intended for wet clutches.

This may not be your problem but it would be the first thing i would check.
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Old 05-09-2011, 01:23 PM   #7
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tranny won't shift

Hi, Just reading your post. I have a similar problem with my 2001 quad 250. I can reach down and shift by hand but it's very difficult, also I've noticed an oil leak beneath the machine. I use atv oil and haven't recently made any changes, also the resevoir window appears full.
Thanks,
Rob
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Old 09-07-2011, 07:22 AM   #8
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Sound like both you guys need to drop the oil weight. If your in snow country try 5-30 oil. I once put 20-50 in my truck after a snow storm and it would not turn over...
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