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Discussion Starter #1
I know this has been done 100 times over but I'd just like some more guidance or ideas. I truly ride an 07 Brute but I came across an old man that had a 2004 Rubicon. Been used on the farm basically not done much with its whole life. But its been sitting for about 6 months to a year. I asked him and he said transmission is junk. He said it runs until it starts to warm up and then slips real bad until it doesnt want to pull. I asked him how much he wanted and he said $500.00 he wanted something new. If the thing was beat up i'd never blinked and eye but its in great shape and if i had to put a trans in I would, but I get bits and pieces from forums about orings bad in them and oil pump bad. Any thoughts would be great. i can work on them myself and make most tools I need. Would make a decent second bike too. I'm gonna order a service manual and pick the bike up this weekend. Guide away. Thanks in advance!!! I don't want to put a $1300 trans in if I can fix it and If it pulls cold wouldnt that be a pressure problem? I've seen it run and it runs great, U wouldnt believe how good shape the bikes in!! Any ideas??
 

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Welcome, It could be an oil pump and/or transmission problem. You'll need to test the oil pressure. It also could just be low on oil. Even if it's a sticky relief valve in the oil pump it probably already did some transmission damage, when I replace them I do both and the new parts you'll get are the updated parts.
 

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Transmission and oil pump. First thing for you is to check the oil level and make sure it's good, idle the bike for 4-5 min then shut it off and let it sit a couple min then check the oil by just sitting the dip stick in the hole.
 

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Discussion Starter #5
Have ya ever heard anything of the orings in the trans breaking or weakening causing not to hold enough pressure?? Keep layin it on Thanks
 

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Discussion Starter #7
Ok thanks so I get the bike check oil and oil levels. I have a pressure tester from work. Test the
pressures and if low consider replacing oil pump first and see what happens. Sound like the first steps??
 

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Discussion Starter #9
Thanks Sportsman but I got one. Thanks though

Alright guys, went and got the bike brought it home. Starts and runs fine rode it around 10 -15 min, you do hear trans noise which I thought in the beginning was engine noise. It does slip when you hit a real steep incline and as it got warmer and finally before I shut it down when sitting in neutral it has a pretty nasty grinding/growling noise. Never stopped pulling but I didnt want to push it too far once the noise got pronounced. Help me out!!! Pull and check the centrifugal clutch??? I'm ready to tear into it!!!

Thanks for any help!!!!
 

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Discussion Starter #10
We worked on the quad tonight and found the following:

The engine oil was beyond bad... probably the darkest, most used up oil I've ever run across.

Didn't find much in the filter, just what looked like some fibers from the clutch. No metal slivers or chunks.

Opened up the clutch cover and didn't see anything out of whack. Clutch doesn't smell burnt, but we don't have the puller to take it all the way off to check further.

Gonna have a mechanic friend double check the front cover bearings to verify if they are good or bad. In any case, they aren't too bad.

My buddy who heard the engine running, said that it sounded almost like a missed shift on a dirt bike (like false neutral). So we were wondering if we have a combo... bad oil, something bad with the gear position sensor and a burnt up clutch? Talked to the previous owner again, and he said when it had this problem, he could shift it with the button shifter and it would work better. Don't know if that is a symptom, but thought it might be.

Thanks for all the help!
 

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I have an 04 Rancher 400 that is doing the exact same thing. Oil is good, clean, and correct for the bike. Nothing in the filter after checking. The clutch was replaced less than 150 miles ago. Im going nuts with this. Need help too!
 

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Do a search on the Rancher Forum outlaw... there is a bunch of info about slipping ranchers.. I think the 04 400At had a recall on the ECM... get your vin and call the local honda dealer and have it checked to see if it was ever replaced .. I'm pretty sure it was the 04 and not the 05... I sold my SOB 05... but my buddy that bought it has it dialed in I THINK
 

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We worked on the quad tonight and found the following:

The engine oil was beyond bad... probably the darkest, most used up oil I've ever run across.

Didn't find much in the filter, just what looked like some fibers from the clutch. No metal slivers or chunks.

Opened up the clutch cover and didn't see anything out of whack. Clutch doesn't smell burnt, but we don't have the puller to take it all the way off to check further.

Gonna have a mechanic friend double check the front cover bearings to verify if they are good or bad. In any case, they aren't too bad.

My buddy who heard the engine running, said that it sounded almost like a missed shift on a dirt bike (like false neutral). So we were wondering if we have a combo... bad oil, something bad with the gear position sensor and a burnt up clutch? Talked to the previous owner again, and he said when it had this problem, he could shift it with the button shifter and it would work better. Don't know if that is a symptom, but thought it might be.

Thanks for all the help!
Did you ever figure out what was wrong? I have a 2004 rubicon and I'm having a issue with the clutch slipping when it gets hot?
 
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