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By middlebrookgt
I have replaced the cracked stator cover on my non-running 2006 LT-F400F that I purchased recently, checked all the shafts vs the service manual and pics and advice here. I replaced missing gears, bushings and washers, made sure that truth marks were all aligned properly, that the shift cam springs felt like they returned properly, etc. IAfter installing the new stator cover I checked the transfer lever for proper movement from L-H-R and then cranked it up. Happily, it runs and changes gears well in L, but it will not shift into H or R for anything. I have opened it back up and am going back through it looking for the missing puzzle piece(s) but how can I best check that I have everything right this time before buttoning it back up?
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By T37Mark
HI everyone. New to this forum. I have 98 Kawasaki Bayou 400 with an apparent electrical issue. I have the Clymer manual, but I am not exactly sure where to start. The issue started a month ago and the neutral light would go on and off intermittently. Eventually it went completely off , and I thought it was a shifting issue. I took the case off and checked the clutch and all mechanical shifting components are good, so I think I eliminated that. The switch sometimes works, sometimes doesn't. Last time I tried, I did hear a clicking sound near where the battery is right before the light went out. Does anyone have any ideas where to start? Hoping this is an easy fix.
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By joezee13
After turning off engine in neutral starter wont engage If I rock unit back and forth it engages Getting progressive worse.
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By middlebrookgt
Hi All. I introduced myself some weeks ago with my 2006 LT-F400F that needed a list of repairs including replacing the cracked generator cover. It is back together as of last night and cranks up, idles and revs high pretty well. Needs some fine tuning and stop backfiring at stop.
The big issue is it will not go into gear. I reassembled the insides with help from y’all’s posts. The transfer selector moves from H-L-R, and the foot shifter moves thru the gears and finds neutral easily enough. Before I tear it back open, the transfer selector on top does not move as far as the repair manual says. The diagram shows the shaft moving something like 40 degrees between L and H and 50+ degrees between L and R but it doesn’t move that far even though it finds the indent areas and moves well.
Could this be the problem. I aligned all the dots on the shifter gears inside and it appeared to not be binding anywhere. I do hear the gears touching when I shift like they are trying to engage, but zero movement from the ARV
It was somewhat difficult to tell whether all the parts are installed on each shaft.
Are there better/bigger photos somewhere that would allow me to be confident I included all the washers and bushings, etc? If I had any doubt on parts that were laying inside after the cover broke then I purchased replacements from online stores.
TIA for any input or feedback!! Pics are from when I first took the generator cover off.
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