1995 Kawasaki bayou 220 won't start

[kaidella]

Bought 4 wheeler for kids. Used to run and soon as it was put in gear it died. I have put new carburater, new plug and battery. The neutral light won't come on. I replaced the solenoid, then the positive battery cable and today put new relay assembly on. Still no neutral light. Not getting any juice and I don't know why.

[dtbprc]

neutral switch somewhere- find it clean it or replace it

[kaidella]

Great. I will look for it. Thank you so much.

[oxidized_black]

you will need that neutral light on unless it was bypassed ... like dtbprc said, could be bad connection or a broken wire ,,, most times the switch is on the flat of the transmission behind the motor, looks like a sending unit, usually just a one wire deal ...

[kaidella]

Thank you. It used to work but quit. I replaced the solenoid, the relay assembly and have ordered a neutral switch. Is it very difficult to install? I've been trying to find out where it is online but not having any luck.

[oxidized_black]

this is what i found on another forum with your 220 ///

There is a switch on the end of the gear change drum that signals when the tranny is in neutral or reverse. It's made of plastic and can sometimes break. More often the contacts are rusted even though it sits in oil.

You have to remove the left engine cover and final drive case to get at the switch. You can often do this by sliding the motor ahead in the frame instead of pulling the motor.

here is a manual for your bike here ... https://www.hightail.com/download/UlRSK2VxZy9tMEp3SGNUQw

[oxidized_black]

there are 2 wires for your safety switch ... you could splice them together to bypass the switch altogether, but if you have kids starting the bike, maybe not ... when bypassed, it can start in gear ...

[kaidella]

I got the manual, thanks. Not real clear though on the switch. I should get my new one in the next day or so. Do I need to go ahead and drain the oil and try to remove the left cover where the pull start is?

[kaidella]

How hard is it to slide it forward? I downloaded the manual but it is not exactly like mine and doesn't say anything about sliding it forward. What all do I need to undo?

[kaidella]

I got the engine forward, now is there a trick to opening the gear case?

[kaidella]

I am so aggravated. Finally got the engine down and moved forward. Got to the neutral switch, which was broken, replaced it, got it all put back together and turned on the key.........NOTHING! I just don't know what to do. Any suggestions please.

[neilroy87]

Did you ever get this resolved?  Having similar issues--does splicing the neutral switch wires together work to get the starter button going?