Bish

Did you put a gasket on the outer casing or just glue it? If you just glued it I would get a gasket and the thickness might give more clearance so the gear doesn't get jammed out

Thanks for the manual

I had a similar problem with a kick-starter on a yz 125. I glued the outer crank case on and it would get stuck. I found that I had to buy a gasket instead of gluing it on. It didn't have enough clearance without the gasket. I found that if I lossened the outer crank case when It was glued it would free up and work fine, that's how I would test it.

I'm not sure if this will help you but I figured the information can't hurt.

Welcome

Welcome

Welcome mate

Hey guys and gals, I am from australia. I have a yamaha big bear 400 4x4. I have taken it out to the local nation park a couple of times and made a rod protector out of 90mm pvc downpipe. Simple little protector, nothing flash just stops my fishing rod getting caught on a tree or something and breaking. I also own 40 acres that I like riding around on and also use the quad to tow a spray tank or trailer around. 

Currently it won't go into 4x4 so I'm here to get advice on fixing that. Cheers

I grew up on a farm so bikes have been a part my life since day dot. I recently brought a big bear 400 4x4 which is min for taking through the national parks. The 4x4 is definetly worth it there's to many time that instead of getting off the bike to get it unstuck I could just wack it into 4x4 and lock the diff and off she goes!

Hey mate I'm also from Australia, queenslander! Looks like it will turn out mint makes me want to give my big bear 400 some love!

Hey, my names kruz. I am from.australia and have a 2008 yamaha big bear 400. She's a bit of a pig but is awesome to ride. 

You may need to adjust the float or clean/replace the seat 

Thanks for the manual