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ronwv48

2001 Kawasaki 300 bayou shifter shaft

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Just got a 2001 300 2x4 Bayou that needs a shifter shaft. Is this a very hard replacement to do? What do I need to watch for? Is there a video on this repair?

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Not that hard to do.  You'll need to remove the right hand engine cover and the 2 clutches in order to pull it out.  There's a few washers and springs you need to watch for so a service manual is needed to make sure everything goes back together correctly.  An air impact is helpful getting those clutch nuts off.  The shaft and a new cover gasket should be all the parts you'll need.  A Kawasaki or Clymer manual walks you through the process.

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@JacobSlabach if you ever come across and old bike laying around that’s shot. Pull the motor and split it open.   I did this with my son on a beat up xr80 we found. He split the engine just to see how things work.   I explained as much as I knew and in addition he learned how the clutch worked etc. It was a great learning experience.  

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Are you sure you put everything back correct ? The shifter has a reverse cam. Have you reinstalled that correctly? It’s a lever that’s got a notch in it on the same side under the same cover.  

 

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This is a picture of the bayou I just worked on.  The part that has the arrow has a notch that allows the shifter to go into reverse when you pull the reverse spring lever.  Did that get messed with during your repair ? 

ED3393E3-E731-47D3-8B02-B3CD007E8910.jpeg

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Is this on the left side by the rev lockout lever?If it is I didn't have it off,just the right side. Is that the neutral/reverse switch

Edited by ronwv48

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I don't remember seeing that when I had it apart .Ill look tomorrow Is that the shifter shaft in the pic?

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Yes that’s the reverse lock out lever. I was wondering if you re installed the lock out properly ? And yes that’s the shifter and neutral safety switch.  

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update grounded green wire to bypass neutral switch. starter works ,sarted up was in reverse so i'm happy. thanks a lot frank for the help    now waiting on gasket to finish putting it back together.

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That’s great glad to help. What parts are you going to order?  That reverse cam was bad not my switch.   But I lightly sanded that switch while I replaced that reverse cam just to clean up the contacts.

The neutral safety topic will help you out. 

Maybe @Admin can help combine all your topics to one so it’s essier to respond and keep one topic going.  

 

 

Btw that part was $12 bucks oem on eBay.   

Gasket kit entire kit amazon $38. Might as well get the whole kit.   Never know 

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If you know how to combine the posts that would be great. Not sure what parts to get now  until I tear the left side down ,just got the right side gasket, should have got the set

ready to put right side back together so I can try it out. I will work on the neutral switch later..I want to make sure every thing else is ok .I just bought it and don't know its history

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If every thing checks out ok i'll probably order parts and do the switch next week. I have tried to download the manual 1986 - 2006 Kawasaki KLF 300 Bayou Service Manual several times and it comes back corrupt. Is there a trick to download it.

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