1994 Bayou 220 Neutral safety switch

[Arizona 16]

On one of the atv I recently purchased the neutral switch is bad, Any one ever replaced one.

looking for some pics. I assume I need to remove the drive shaft to pull the cover foward

to clear the gear shift shaft. Any easy ways to do this. So far have motor moved forward 

all bolts out except nuts on drive shaft which are loose Thanks Az

[Frank Angerano 837]

 

 

[Arizona 16]

Great man, exactly what I needed to see. Let you know how it goes. Az

[Frank Angerano 837]

No worries.  Most likely not the neutral safety switch. It’s the reverse cam. Read that post and you will see the contact point on the revers cam that’s spring loaded.  The spring loses its bounce and the contact rod has a problem grounding the switch.   Just be sure to sand the switch a bit before you reinstall.   Good luck. 

[Arizona 16]

Well already ordered one and cant be returned cheaply so ill just replace it. Have switch off

ohms out ok then goes open then ok etc. might be me moving the contacts lol. I did ohm the pin

on the reverse stop to ground and not liking the readings so I ordered a new one anyway. Cheap insurance

while in there. What holds the reverse stop in on that shaft? is it just floating there. Just remove the c clip and 

the tensioner and it slides out?  Some pics for your enjoyment

[Frank Angerano 837]

Yes you have to replace that reverse cam stopper while your in there.  The neutral safety switch is not really a switch. It’s just two contacts on a board.  All I did was sand the surface down of the switch and replace the cam stopper.

Put a shit load of grease on the bevel gear and shaft before you reassemble.  

When you put the drive shaft back the four bolts, tighten them in a crisscross pattern and use a little thread lock or a dab of silicone on the nuts when they are tight.  

Nice work and great pics.  

[Arizona 16]

Well the reverse cam stopper showed the other day so I installed it and rechecked the readings on the 

switch. I showed good so I just sanded down the switch like you said and installed it. Put it all back together

and now I get a neutral light and im sure its gonna crank when I get a battery. You nailed it. Just a 12 dollar

part and some labor and it seems fixed. Thanks for the info. Now the 220 is out of the paint shop, some pics Az.

[Frank Angerano 837]

Right up my alley!!! Nice work brother.   I had a feeling it was  the reverse cam! That looks great.  Keep the pics coming and check out my last post on the Mojave rebuild, it came out sweet.   I’m really digging all the rebuilds that have been going on so far!