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We just bought 4 acres and needed a work rig for moving stuff around and blazing trails. Been looking at buying a quad for a long time and finally got the opportunity. Found a very good condition 1994 Kawi Bayou 300 4x4. Runs great and seems to be in great operating condition with one little thing.
The unit seems to have an issue with reverse. Previous owner did tell me about it and its totally usable but the issue is annoying enough that I want to try and fix it. Im pretty mechanical oriented so don’t think this will (hopefully) be too much of an issue. I bought the kawasaki shop manual on ebay and should be here next Friday but wanted to get a head start on it.
The issue seems to be similar to this post but I think may be more mechanical than just the switch.
Neutral light is always on when key in on position I found that the green wire coming out of the block from neutral switch is grounded to chassis. When plugged in to switch light never turns on no matter what gear its in (and wont start). Machine can go from 1st directly into Reverse if you don’t feather it. This is the part that that makes me want to fix it. I feel like its dangerous and could possibly do some damage. It usually takes 3-4 tries to 'find' neutral. The reverse turn knob seems to be operable and cable is connected and operates the reverse 'selector' when turned. Springs back when released both at the switch and at the 'selector' inboard of the shifter. When in reverse the red reverse light does not illuminate Based on above and looking at the post above it seems that this would indicate that the reverse stopper is 'broken' and rotated in an 'in gear' position. I see a few posts on here where people have said it can crack. If I plug the green wire back in and turn machine to 'on' I can move the shifter through all gears and the neutral light and reverse light stay off. Again, to me it seems that the 'reverse stopper' is probably broken, stuck where the switch thinks its in a forward gear and the shaft is probably just spinning inside it.
Am I on the right track here?
I wanted to get a head start on this and looking at parts diagrams it looks like the part number for the 'reverse stopper' is 13091-1443, found one on ebay for $30 shipped. I hate buying parts before tearing it down but if this is the likely culprit I would take a $30 gamble to buy it so I can have it on hand when the manual arrives.
The other question I have which I hope is an easy answer is none of the parts diagrams I have found show the bevel gear gasket part number. Can anyone tell me what the part number is for this?
Many, many thanks for the info and I promise to post pics once I have it apart.
So, I just bought this quad off a acquaintance of mine… anyways, it’s missing the airbox which I’m trying to purchase if I could only figure out the year and what model of lt230 it is due to having only 9 visible digits for a vin…guy said he had the title at one point and lost it when he moved houses after the flood of 08 in Iowa….I just desperately need to know what model this thing is so I can start getting to work on it….it does run after a good carb cleaning….I’m having trouble getting it to idle though due to essentially just having a rigged up air filter with no airbox on the bike…I’ve sanded down the plastics and it looks like the original color was orange and the seat I believe is either from a different Suzuki or it’s been painted gold and black? The plastic nose part is originally black…it has the lever for reverse by the sprocket it has a pull string to start and I think originally it has electric start as well….idk I’ve had to bypass and use a screwdriver on the starter Solenoid to get it to start …someone has definitely done some rigging with the wiring as well.but if anyone has any clue what I need to look for to identify the year and actual model so I can get the right stuff. I’d appreciate it.
Need new tires for mostly plowing and running around. Found some good tires.
specs call for front 26-8-12 Rear 26-11-12
Has anyone put 27-9-12 & 27-11-12 as more of selections going up on front and taller
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