2001 Kawasaki 300 bayou shifter shaft

[ronwv48]

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?

[Frank Angerano]

That’s a good question.  I would refer this to @wanrep   He’s got some good info/knowledge  on stuff like this. Maybe he can help.  

[wanrep]

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.

[ronwv48]

tthanks for info ill let you know how  it turns out

 

[JacobSlabach]

I'll be following along on this thread too- curious as Iv'e never had to dig into the crankcase of a bike

[Frank Angerano]

@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.  

[JacobSlabach]

will do first shot bike I come across!  👍

[ronwv48]

Got shaft in ,not a bad job ,but now no reverse ,any help appreciated

 

[Frank Angerano]

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.  

 

[Frank Angerano]

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 ? 

[ronwv48]

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 March 12, 2019 by ronwv48

[ronwv48]

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

[Frank Angerano]

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.  

[ronwv48]

I'll check that out today,thanks for the help.

 

[Frank Angerano]

👍🏻

[ronwv48]

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.

[Frank Angerano]

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 

[ronwv48]

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

[Frank Angerano]

Ok I hear ya. Let us know how it goes.  As far as the neutral safety switch it’s not bad to do.  

[ronwv48]

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.

[Frank Angerano]

I don’t know.  I’ve never had a problem but @Admin or @Ajmboy maybe can help you out. I know they double check there downloads for any problems prior to adding them to the library.   

[Admin]

2 hours ago, ronwv48 said:

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

PM me the urls of the topics you would like to combine and I can do that for you.

1 hour ago, ronwv48 said:

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.

The manual was an external source. I've downloaded it and checked it out. I compressed it and re-uploaded it, so it should work.

 

[ronwv48]

Well I got it back together today. neutral switch was bypassed, ok  reverse lockout didn't work, ok  Found gears ok, except couldn't find 4th. and 5th. gear  Could the reverse lockout be blocking those gears. run fine, shifted fine. happy for right now with 3 gears and reverse.. think it will work out in the end. any thoughts on the gears? 

[Frank Angerano]

I would not be happy for too long.  Somethings going on obviously. A spring is not is installed on the gears maybe or a gear reinstalled backwards etc.  Something was missed.  That reverse lock out can can be looked at while the cover is off do functionality.   Review the work you’ve done and go back and look if you can.   You will find it.  

[ronwv48]

trying to think I replaced the shifter shaft didn't take the other side apart. Don't look like it has been worked on, wish I knew it's history. i'll tear it down to see if  can see anything.  I'm guessing someone had trouble shifting and kept kicking it till they broke the shifter. thanks  i'll  let you know what I find

[Frank Angerano]

Oh ok so you don’t know what happened prior to the shaft being broken. I didn’t realize that.   Yep well it was most likely broken due to something breaking inside and someone prob beating on the shifter. 

Is is a 4x4? 

Honestly I would think about it and make a decision  if the bike is worth pulling the engine off and  tearing into it.  If the bike is clean and in good shape and if your able to do the work yourself or have someone help you?  If so then go for it!

It may be something simple inside the engine partswise and more of a labor intensive thing like having to pull the motor. And keep in mind  the neutral safety switch replacent requires you to pull the engine mounting bolts out and shift the engine over to get the cover off anyway. Unless you pull the shifter shaft out again because the shifter shaft does not allow the cover on the shifter side  to come off without moving the engine over. 

 

[ronwv48]

I'll check the left side to see if something there is blocking it and recheck the right side to see if I got it back right. I don't want to tear into the trams.  maybe up for sale every thing else seems good.  Later

[ronwv48]

2x4 thanks for the good info..  i'll pull shifter shaft  hope I don't have to pull motor. I am age restricted for to much labor and lazy too.  71

 

[Frank Angerano]

Age is all mind over matter.

If you don’t mind it don’t matter!!!! 

Good luck with the work and any questions you have you will find answers here !

[JacobSlabach]

and if something wasnt put back right, I would check it out before riding as you might cause more damage if something is flying around in there lol