Just did full rebuild, no neutral????

[Btown440EX]

I need some help please!!!!!!!! This winter I did a full engine rebuild, I mean everything is new. 440 big bore, stage 2 cam, hd cam chain, full hinson clutch, hd springs. Engine fired right up, sounded good, no unusual sounds. I put the chain on, pop it in neutral the light lit up, go to push it into the yard and it wont roll, it acts as if it is in gear. But if I pull the clutch in it rolls fine, but as soon as I let the lever out it locks up even when everything indicates it is in neutral. I don't know where to start, anybody ever had any problem like this before or know what could be causing this? I would appreciate ANY information. Thanks! Luke

[a4guy]

When the quad is running and the (N) light is on is it actually in gear?

[flyjum]

Regardless of what the light says does it still have all the gears and neutral like normal?

[f4iracer]

yeah start that thing up and put it in neutral.

[4reeds]

adjust the clutch cable

[a4guy]

Why would adjusting the clutch cable change anything? If its in neutral it will roll with or without the clutch engaged.

[Btown440EX]

it is in gear when neutral light is on, but it does not shift correctly, and it locks up when I hit fourth gear, makes a bad grinding sound. Could this be bent shift forks or did I install the transmission wrong?

[a4guy]

Sounds like something is not lined up correctly. Are you sure you installed the shift forks the right way? I would not run it like this at all. You will turn some gears into scrap metal.

[Wheelie]

Split the cases before you really tear something up.

Personally when I rebuild a quad transmission, I shift it through the gears by hand before I'm done assembling the engine. This way I'm sure neutral and all the gears are there before the engine is installed.

[a4guy]

Originally posted by Wheelie
Split the cases before you really tear something up.

Personally when I rebuild a quad transmission, I shift it through the gears by hand before I'm done assembling the engine. This way I'm sure neutral and all the gears are there before the engine is installed.

I second that one.

[Btown440EX]

Thanks for all the advise guys, today I split the case and discovered that I had one of the shift forks flipped over and when I started it up I had nuked 1st and 2nd gear. I will now check the transmission to make sure it shifts before I button up the engine this time.

[a4guy]

Sorry to hear you had issues. Glad to hear you figured it out.