Technical Conversation about ATV Transmission Types
Preface:
I've always looked at ATVs as tools rather than a toy. I have always used Hondas with the semi-automatic style transmission with an electric thumb shift. These were always a little jerky but great for going slow and pulling hard (logging, fencing, etc) and the electric thumb shift allows us to ride side-saddle. From my understanding, these transmissions are the exact same as the foot shift models, just with an electric shift motor located in place of the traditional foot lever.
Seems that Honda has abandoned the electric shifter for current models to simplify the product line to just foot shift and the DCT expect for one lowly Recon model. Honda also makes an automatic transmission that they used in the Rincon for forever. This has sent me down a rabbit hole of trying to understand the various transmission types for looming future purchases since Honda has abandoned the electric shift in the Foreman.
Additionally, we recently purchased a Ranger 1000 Crew which I believe utilizes a similar transmission to the sportsman models. You cannot go slow and moving the machine only a couple of inches isn't really possible.
I figure this would be a good location to try to consolidate all this information for others and ask for additional input from y'all. Please feel free to correct me and let me know if you'd like anything to be added or removed; I am by-no-means an expert. Also, feel free to share personal ancedotal experiences below. Many of the comments are purely based on experience.
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From my understanding, there are 5 distinct types of ATV transmissions:
- Manual/Semi-Automatic
- Dual Clutch Transmission
- Automatic
- CVT
- Unique Features
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Manual/Semi-Automatic
These are the traditional, dirt bike-like transmissions with an internal clutch plate like would be found in a 'standard' automobile transmission. Internally, the manual and semi-automatic transmissions are mechanically very similar (Confirm?). I don't believe anyone manufactures manual clutch models anymore; Honda still makes semi-automatic models.
- Manual models utilize a hand or foot actuated clutch lever to depress the clutch. Reserved to very early ATV models (Confirm?)
- Semi-automatic models utilize a automated, mechanical system (Confirm?) to depress the clutch.
Pros
- Fully sealed system
- Tried and True
- Can be very smooth with an experienced operator
- No belt to shred
- Slow speed operation
- 'Simple'
Cons
- Jerky shifting between gears for inexperienced operators
- Manual clutches can be stalled
- Semi-automatic requires more complexity due to automatic clutch
- Finite number of gear ratios (5 Speed)
Models
- Yamaha Raptor/YFZ (Manual)
- Honda Foreman/Rancher/Recon (Semi-Automatic)
- Lots of older models from various manufacturers
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Dual-Clutch
Similar to the dual-clutch transmissions seen in some newer automobiles, these are basically two manual transmissions that alternate gearing. This allows one clutch-pack to near-instantaneously engage as the other disengages.
Pros
- Fully Sealed System
- Smooth Shifting
- Should one clutch fail, half the gears are still available (Confirm?)
- No belt to shred
Cons
- Complexity
- Price
- Weight
- Finite number of gear ratios (5 Speed)
- Unknown long-term reliability
Models
- Honda Rubicon
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Automatic
Again, similar to those found in automobiles. Utilize a torque-converter instead of clutch packs to decouple engine and transmission.
Pros
- Fully Sealed System
- Smooth Shifting
- No belt or clutch plates
- Tried and True
Cons
- Complexity
- Price
- Weight
- Size
- Finite number of gear ratios (3 Speed Only)
- Requires frequent oil changes (Confirm?)
Models
- Honda Rincon
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Continuously Variable (CVT) - Dry Belt
Quintessential ATV/SxS/Snowmobile Transmission. Utilize a rubber belt and cone-shaped pulleys to vary the gear ratio. Rely on friction between belt and pulleys rather than friction between clutch plates or a torque converter.
Pros
- Inexpensive
- 'Simple'
- Infinite Gear Ratios
- Easy to Wrench
- Fun Factor
- Speed/Acceleration
Cons
- Unsealed System (Belt)
- Belt slippage during acceleration
- Belt slippage due to water/mud
- Constant speed grooving in pulley
- Possible poor clutch engagement at low speeds
- Tried and True
- 'Frequent' Belt Replacement (Mileage may vary)
- Belts will degrade just due to time
Models
- Can-am Outlander (pDrive?)
- Polaris Sportsman
- Kymco/Arctic Cat/Kawasaki/Argo
- CF Moto CForce
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Continuously Variable (CVT) - Wet Belt
Same as dry-belt above, but it incorporates an internal clutch pack to decouple engine and transmission. As a result, belt stays tensioned all the time.
Pros
- No shifting
- No belt slippage during acceleration
- Infinite Gear Ratios
- Tried and True
- Fun Factor
- Speed/Acceleration
Cons
- Unsealed System (Belt)
- Belt slippage due to water/mud
- Horsepower losses compared to dry-belt
- Constant speed grooving in pulley
Models
- Yamaha Grizzly/Kodiak (Ultramatic)
- Suzuki KingQuad (Quadmatic)
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Unique Features
Hydrostatic:
Usually reserved for small tractors, lawn mowers, or heavy equipment, Honda had a hydrostatic transmission from 2001-2014. The engine drives a hydraulic pump which drives corresponding hydraulic motors on each axle. High torque but also high power losses.
PTO:
Yamaha produced the TerraPro from 1988-1989 that featured a PTO shaft out the rear. Implements include a rough-cut mower, finish mower, tiller, and sprayer (Others?)
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Personal note: Honda ATV models overlap quite a bit and I cannot discern the distinguishing factors between them. In this respect, I am referring to the models based on:
Rincon: Automatic (Now the Rubicon 700)
Rubicon: DCT w/ IRS
Foreman: Semi-automatic w/ Solid Rear Axle
Rancher: Smaller version of Rubicon w/ Semi-automatic
Recon: Smaller version of Foreman
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Edit: Added Yamaha Raptor as a Manual
Edit 2: Changed Terminology from Wet-Belt to Wet-Clutch, Reworded slow speed difficulty for dry-belt
Edit 3: Added Fun Factor & Speed/Acceleration to CVTs, Reworded 'Frequent' belt replacement under dry-belt
Edit 4: Added Hydrostatic
Edit 5: Removing Hydrostatic and Adding a 'Unique Features' Section.