Clutch Troubles....please help - Yamaha Grizzly ATV Forum
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post #1 of 8 Old 12-23-2009, 12:05 PM Thread Starter
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Clutch Troubles....please help


1. 2002 Big Bear 400 4x4
2. Friend's kid's ran it low on oil because they lost the oil fill stick.
3. They had some guy up north look at it and got it running
4. ATV ran with limited range only 20 mph max speed.
5. I look at it, and lots of ticking, adjusted valves.
6. Ran great for 5 mins down the street and locked up.
7. I tear apart engine and found the piston pin had sheared off
8. Put a big bore kit in. New piston etc...
9. Ran great, moved and everything.
10. Head gasket seeped oil.
11. Removed head only and had tested.
12. Cam was bad and replaced
13. Installed head, and runs great.
14. NOW IT DOESN'T MOVE, tried the clutch adjuster and nothing. It does click into all gears including reverse but doesn't move.
15. Another mute point, it's been siting for 2 days and the carb started leaking LOL - easy fix but just wanted to complain as I want this thing out of my garage finally. LOL

SO my question is.......what should I check first??? I really don't want to drain the oil and pull the side casing off if i don't have to but just looking for a plan of action. Another side note is it has been 6 weeks as I had to wait for the Head to return if that matters.

Thanks ahead of time,
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post #2 of 8 Old 12-23-2009, 08:24 PM
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The very first thing I would check is the price of a new Grizzly..........................
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post #3 of 8 Old 12-23-2009, 08:37 PM
I Mucked up AGAIN?!?!
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Damn Jack....I was going to say the same thing...
Putting an awful lot of work into something you can sell on CraigsList then use that $$$ towards something currently running...

Check out My Garage...IT'S FULL!!!!

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post #4 of 8 Old 12-24-2009, 12:16 AM Thread Starter
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Thanks for the sarcasm guys. The big bear is not mine, I'm just repairing it, and the atv mechanically runs great engine wise. Just curious if there is something simple than pulling the case off to inspect why the clutch is not engaging.

Again, if you could help that would be appreciated.
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post #5 of 8 Old 12-24-2009, 12:52 AM
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Hmmm.......stripped gear?
post #6 of 8 Old 12-24-2009, 12:00 PM Thread Starter
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Could be. Before I removed the head because the new head gasket seeped oil it ran and moved great. I didn't do anything to the engine case or clutch cover, just simply took the head off. So it's a little baffling that it won't move. The gears click into position, reverse on up.

Looks like I'll drain the oil and pull the covers off to take a look. I'll do that this weekend and let everyone know what I find.

Perhaps it's a loose nut behind the wrench?? LOL

Any advice on what to look for specifically that would cause an issue with the clutch not engaging while in gear would be appreciated. Or if anyone knows of a service manual online detailing the clutch system would be great.
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post #7 of 8 Old 12-25-2009, 07:36 AM
RIP Mike Mayho
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I don`t on a bb but on a honda when you move the shifter there is a piece of linkage that disengages the clutch 1st then moves the gear position. maybe that piece got stuck and not letting the clutch engage.

Signature edited by GEARSLAYER in respect for the great late Mike Mayho known to us as Mad Mike. Mike's no longer with us people.

Mike road a mean...
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post #8 of 8 Old 04-12-2010, 02:40 PM Thread Starter
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Sorry for not closing this, but I took apart the clutch and re cleaned. All I can think of is that I didn't have the springs torqued correctly the first time I put it together. Clutch works great but now I have a different problem that I'll post.
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