No Neutral after rebuild

142 Views 2 Replies 2 Participants Last post by Bullvine rider!!, 12 d ago

Hoonigan82

Discussion Starter · 13 d ago

Did a rebuild on my 07 trx450er because the crank started leaving brass shavings in the oil. Only things i didn’t replace where the trans components because they are not affected by the crank shavings.

i was very careful to pull out the trans gear shafts and not disturb them at all while i was in the motor. I put everything back together and before putting the chain on i ran some heat cycles and it starts up fine idles fine and sound good other than valve ticking i need to adjust.

I go to put the chain on to take it up the street and my neutral light is coming on but the quad doesn’t seem to be in neutral. When i pull the clutch leaver in to rock the bike back and forth the clutch doesn’t seem to be disengaging also so no matter what gear i go into when i pull the clutch leaver i can freely roll the quad. Also when i push the shifter down a few times to signify that i would be in 1st gear when i try to shift up into “neutral” I actually go into i guess 2nd and hear an odd click from the shift pawl in the shift star then the shifter will not move back into first it get bound up almost so i have to shift up again then it seems to free itself and i can go back down to get into first

Im hoping with these detail’s someone could give me a place to look. I dont believe its an issue in the trans I believe its an issue with the shift mechanism but I double checked everything and i cant seem to find what would cause the clutch to not disengage, the shifter to lock up, and no neutral.

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Bullvine rider!!

· #2 · 12 d ago

Im not too Savvy with transmission work. Figured id respond since no one has yet. So you replaced the clutch assembly correct? Sounds like your shift dogs may be worn out, I hear lots of people and companies cut them back, the 06+ have weaker transmissions. Could be the shift fork as well.
like I said I know very little about these trannies, just trying to help.
how did they look when you pulled them out?
And are you positive you assembled everything correctly?

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Bullvine rider!!

· #3 · 12 d ago

Bullvine rider!! said:
Im not too Savvy with transmission work. Figured id respond since no one has yet. So you replaced the clutch assembly correct? Sounds like your shift dogs may be worn out, I hear lots of people and companies cut them back, the 06+ have weaker transmissions. Could be the shift fork as well.
like I said I know very little about these trannies, just trying to help.
how did they look when you pulled them out?
And are you positive you assembled everything correctly?

I ask about the clutch assembly cuz usually your basket or friction plates or both are grooved and worn out when you have those symptoms. But if you just recently replaced all that as part of the build then it could be more serious like worn dogs or shift fork.
hooe to hear back from you.

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