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wrote:
The engine still start and be able to do backward.
Have you checked the shear pin?
If the pin is intact, this sounds like the rubber cushion hub has spun
inside the prop.

Yes, it make some chunking noise.
Not a good sign.

We shifting it slow with the black lever, the gear lever.
We always did that or try to did that.
Bad, bad, bad. That was a trick question I posed. The foot on that
kicker is very sensitive to the shifting technique - it must be a firm,
brisk, deliberate snap into & out of gear at the lowest possible
throttle setting. You will quickly ruin the gearset & clutch dog with
slow shifting and too high engine speed.

In a few incidents when we bring
it down to idle and it stalls with the gear stuck at forward or
backward. When it happens then we will not be able to start the engine
but to move the black lever back and forth to release it from gears.
You lost me on that one. It sounds like the shift fork in the foot
might be bent or worn.

When that happened that day, it was very slow even with the red lever
forward all the way and at the end it was not even moving with gas.
Sounds like the prop hub slipping again. Does the engine overspeed or
rev high in this condition?

Rob

There is not much slop in the linkage.

Thanks for your help !!!