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please help 2001 zr 600 efi stuck in reverse wont engage in forward

12K views 19 replies 4 participants last post by  justincase  
#1 ·
please help im outside freezing haha and trying to diagnose my sled i just got. rode ok yesterday today i noticed it had low/no fluid in the drop case no leaks tho. now it wont go back into drive it will go in reverse when it engages at 4800 rpm but no forward. anyone know how to tighten the belt? or do i need a new clutch? any info will help me greatly thanks
 
#2 ·
Neither, have you checked that the chain tension is not too tight?
Should only be finger tight and back off 1/4 turn and locked.
Also, can you move the lever at the case?
 
#5 ·
The chain tensioner should be on the side of the chain case. The chain case is on the right side of the sled (when sitting on it). There should be a bolt with a jam nut.

Raise the back of the sled to free up the track. Loosen the jam nut then tighten the bolt, finger tight only. Then turn the bolt 1/4 turn out. Tighten the jam nut. While you're there check the fluid level in the chain case. You'll want the sled to level when checking the fluid.

The cable for the reverse should be in this area too. Check it for wear, rust or kinks.

If you can, securely raise the back of the sled so there is 5-6 inches clearance between the ground and track. Start it up and see if it works.

Is this the first time you've used the reverse?





Umm, do you work for SafeAuto?
 
#6 ·
nope i have used reverse and forward both when i was riding it and now its just stuck in reverse it wont go back into forward it seems to be jammed in the dropcase or something. i dont know if it has a reverse cable it looks like a lever to like a shaft in the dropcase please any more info you may have? that chain tensioner may make it stick in reverse?
 
#7 ·
Arctic Cat use's mechanical linkage's in those chaincase's.
What you are calling the drop case, is the chain case.
The adjuster bolt goes in the front of the case.
If the shift lever and linkage's are all in good shape, and not jammed somehow.
And if chain adjustment does'nt cure the problem, you'll have to open up the chain case to find out what's jammed.

Rick
 
#9 ·
The adjuster is probably right behind the silencer canister, as you look at that side of the sled.

Here's a link to a downloadable service manual for the 2001's
http://rapidshare.com/files/242395046/Arctic_Cat_2001_Service_Manual.exe

All the info you need should be in there.

Rick

Here's a pic of the adjuster.
Granted Mine's a 98, without reverse.
But the adjuster location is the same.
Click on the pic and view at full size, it's circled in red.
 
#10 ·
yea what else could it be thats making it stick in reverse? im new to this whole centrifugal clutch shit. im a dirt/street racer this snowmobile sstuff some of it is alien.. and im very mechanically inclined or able should i say the at the least
 
#12 ·
If the chain is too tight, it can make the shift work hard or jam.
The chain is not active in the shift process, there are some gears in there that allow the direction or rotation to change.
There are some small parts in there that do wear and can fail too.
 
#13 ·
so is that my only possibility is in that box? i hate taking wrong things apart but im gonna tackle that right now and if thats the only thing that could make me stuck in reverse i must do it. it jsut sucks doing the hard thing when its really just the simple un thought of thing like whoops is it out of gas before you kickstart your bike for half n hour lol
 
#14 ·
Did you bother to download the manual I linked you to? Read it?

If you've had the chaincase opened, you should be able to at least manually take it out of reverse.
Then just don't use the reverse, until you have better weather, or more time to work on it.

Rick
 
#16 ·
I'm assuming you're doing all this with either the track lifted off the ground, or the sled laying on it's side.

From your first post it sound's like you were running the chaincase without any lube, something could be siezed.

Those gear's should move freely in there, if they don't then you know where to start.
with the chaincase open, try moving the gear's in and out of reverse by hand.

Also check if anything is jammed up with the operating handle.

Both should move freely, if the gear's don't, you'll have to tear down the chaincase until you find what's jamming it up.
If the handle is jammed, you'll have to track it through the linkage's to the chaincase til you find the problem.

It's a fairly simple mechanical system, so it should'nt be all that hard to troubleshoot.

I know it suck's having to work outdoor's in cold weather,.
Don't let it get you down, you'll figure it out.

Rick
 
#17 ·
thanks man but i dont understand what makes it go back into forward? does the gear have to be pulled out? are you familiar with the sled im referring to? the linkage has been removed as well as exhaust and silencer box now ive had the case open three times now. the lever that pulls the gear out by the clips that looks like a flapper wont pull the gear out of place and engage it with the other gear.
 
#18 ·
A.C. chaincase's have'nt really changed much since the late 80's.
If the change lever inside the case does'nt move the gear like it should, you've already narrowed it down to those two piece's.
Either the lever is siezed on its shaft, or the gear is siezed on it's.

Try using some penetrating oil, like Kroil, or Penetro, or even WD-40 on those piece's, and see if you can get them to break free.

At this point your best bet is to tear down the inside of the chaincase, clean and lube everything in it, including the reverse lever's.
Reassemble and check that everything function's as it should, and fill to the bottom plug with any good chain lube.
Personally I use ATF in mine, and have not had any problem's.

Good Luck
Rick
 
#19 ·
the gear works by two fork flaps pushing the gear out by pulling on the rings and making the gear come into contact with tho top gear which makes it spin the other way correct? so i dont understand why all the mechanical linkage wont pull the gear out i can pull it out with my hands it goes in and out doesnt appear anything is seized they all spin when i lift it off the ground i can spin the track and when i slowly pull it over it spins the gears its just appearing that the linkage isnt strong enough to pull the gear out