Picking up my all-time dream quad, the LT500 "QuadZilla" (this particular one is of 1990 vintage). The problem is with second gear. Shifting from first to second results in the quad locking up the rear tires and stalling. If you bypass second and go to third, the quad is fine. The previuos owner was told it is either second gear or the shift fork. Personally, I am leaning towards second gear being frozen and unable to turn, hence the rear tires locking up and the bike stalling.

Any input would be appreciated!

 

Well, get ready to spend some money. You have come by one of the infamous problems with a used Zilla. They have too much power for the transmissions and end up eating them up. They also shift so good that people dont always clutch them to shift. Sounds like a shift fork is bent or eat up real bad on one side. That wouldn't let the slider move over far enough and try to lock into 2 gears at once. Go ahead and pull the engine out of the frame and get ready to split the cases. You should also inspect everything else closely while it's down. Crank bearings and seals WILL BE A MUST for sure.

 

The engine has less than 10 hours since the rebuild. It has new crank bearings, seals etc.

Based on the given possible reasons for the tranny problem, do you think there is a risk of engine damage occuring if the engine is running. Also, if there is no metal shavings or chunks in the tranny oil, can we assume that the shift fork and/or gear isn't tore up? This is why I am leaning towards the gear being frozen on the shaft versus something being eaten up.

 

This is going out on a limb, but maybe he installed the shift forks wrong/upside down. The first time I tore into a tranny I did that, but then again the bike wouldn't shift at all, so maybe not. As for assuming that the gear and/or shift fork is not tore up, it doesn't sound like it is, but you never know until you rip into it. Either way, good luck with the teardown. Like stated beofre, I would go through the whole bike and replace every bearing/bushing on the bike and in the motor. Just out of curiousity, how much did you pay for this thing?

 

well second gear is a problem . does sound like the shift forks . maybe broke or bent . if you open it up and find what ya need let me know . i have several of gears and shift forks laying around from stuff i have bought .

as far as damage ... if it does break then you are going to have shrapnal all in the engine . the aluminum is easily eaten up by the gears and might not show real well . get a manual for sure . it shows how the gears break down and proper placement .

 

The engine was built by a reputable builder. The tranny was not gone through at the time the engine was built by choice of the previous owner. He put 10 hours on the new build and then the tranny problem arose. His wife wasn't happy about him having to put more money into it after dumping about 6 grand into it up to that point, so she said it has to go. He isn't happy about having to sell it. I know how that feels, I have had to do the same in the past (though, not because someone else told me so).

At any rate, i'm getting the quad plus a bunch of extras in trade for 2 rifles and a pistol. I've been in love with the Zilla ever since I was about 10 years old. Finally get to own one.

donzilla,
I'll get her apart and give you a shout on what parts I need. If you have them, great! It will probably be after Christmas, though. Funds are always tight this time of year.