Ok..my brothers 03 Scram 500 was in to get the gear case fixed. The chain snapped and put a hole in it. Anyways the dealer welded it back togther, great job. Got the bike home last night. He took all the plastic off before he sent it in. He put it all back on last night and tried to drive the bike. He hasnt put a new chain on yet, only wanted to drive it in awd, so jsut the front tires would pull it. He Just wanted to see if it would run.

The problem is the nuetral light is on, he can shift it into drive, or reverse, the front shafts rotate, but the front wheels dont turn. Any idea? Maybe just a plug off somewhere...maybe somone can give me an idea on where to look. I know the plug right behind the pull start, if thats unpluged the bike wont start at all..as soon as i plug it in, the nuetral light comes on. Thansk guys!

 

check out the shifter rod that runs from the shifter to the tranny,mine bent and wouldnt shift into the gears..

 

It is bent some..the dealer pointed that out, but you can still feel it shift into gear..plus like i said, the front shafts spin, just no power goes to the tires...

Also, if you look at the rear sprocket, when in drive it moves forward, when in reverse it goes into reverse. The problem seems to be that it wont go into AWD..but the neutral light still stays on.

 

For the AWD to work it has to sense the rears spinning 20% faster than the fronts....maybe with no chain it doesn't realize it is spinning and should be putting power to the fronts?

 

I don't think it's that. I've driven mine when the chain popped off. The front hubs aren't engaging for some reason. The plug for gear selection may be disconnected on the tranny. It is on top of the tranny near wear the gear shift goes in. If not the dealer messed the switch on the inside of the tranny.

 

Yeah...hes drivin it before with no chain, so thats not it. Also, that plug is on, if you mean the one behind the pull starter. If i unplug it, the bike wont start, but as soon as i plug it in, the neutral light comes on.

 

it sounds electrical to me

Like fishslab said, the fronts arent engaging.

Trace your wires,,,check your fuses, connections, and check your linkage.

sounds like a simple fix,,,yet frustrating

 

did the same person take it apart and put it back together?

 

I'm not sure if we are talkin about the same plug. The one I am refering to is on top of the tranny. Look where the shift linkage connects to the shift arm on the top of the tranny, from the recoil side it will be to the opsite side on top of the tranny. It might be necissary to remove the air box to get to it. This is the f/r gear indicator switch. If the wire is hooked up then there is a little spring loaded ball bearing on the inside that rides on a notch in the shaft. If it was apart the mechanic may have not got this put back together correctly. I don't remember if it can be repaired from the outside if thats the case.

 

Is the AWD light coming on on the handle bar switch?