LT500 wont shift

[GeneW]

I have an LT500 and had the engine rebuilt. The rebuilder claims that it dry shifted fine when he was done with it. In the bike, it will only shift first and neutral when the motor is running. He suggested I check the clearance on the shift lever and then pull the clutch cover off to see what is going on.


I have checked the clearance and the shift lever is not hitting anything. I started taking off the clutch cover but it seems to be binding on the clutch side. I have the service manual and it seems to indicate that just the bolt need removing. Am I missing something in pulling the clutch cover off?

Any other suggestions?

[90Zilla]

You remove the clutch cable?

[zillaguy89]

kicker lever? haha j/k

the footpeg and brake lever need to come off that side too. I'm guessing you've gotten that far though, or it was never put back on yet in the first place since the motor just got done.

Is the clutch chaft tension bolt (i guess one could call it that) loose? I mean the 10mm/phillips head bolt facing forward directly under the cluch lever on the case? Thats my only logical guess. its been a while since I've pulled a clutch cover though.

[Skully]

Are you spinning the countershaft sprocket when you are trying to shift it, a dry trans is hard to shift. Try that first, then take out the bolt that locks in the clutch shaft and pull out the clutch shaft. After all the bolts are out, you will have to wiggle the case off around the kickstarter shaft/seal, the case doesn't just fall off.

Good Luck,
Jim

[NewportHillClimber]

when you get it apart on the right side of the shift shaft are some fingers that need to be aligned with fingers on the shift drum mechanism if they are lined up a notch high the shifter will only go up so far and not shift to second.

[sblt500r]

if you pull back on the clutch arm, it will sort of put pressure on the cover and pop it off.

[GeneW]

Thanks for all of the ideas, I will try them tomorrow and see how it goes. To answer a few of the ?'s, it was fully in the bike and running but only went in first and neutral. Now I am trying to figure out why as the guy that rebuilt the motor claims it was dry shifting fine when he finished and another shop put the motor back in the bike. From the ideas here at least I will be able to get a little further tomorrow.