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'86 bayou 300 - shifting into 1st gear issue

steve-in-ga

By steve-in-ga
in Kawasaki ATV Forum

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steve-in-ga Newbie

steve-in-ga

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I'm having an issue shifting into 1st gear from neutral. No problem shifting into any other gear including reverse. When I depress the foot pedal it doesn't go into 1st gear. After repeatedly pressing it sometimes it will go into 1st gear, other times I have to rock the machine slightly and then it will go into 1st gear. I took the right side cover off and removed the clutches to get a better look. I've taken all the parts of the shifting mechanism off thinking I would find a worn part but everything looks fine. When I watch the shifting action from neutral to 1st gear, the part that engages the shift star (drum) is pushing on the peg that is connected to the shift star but it can't push it far enough down to get it out of neutral before it bottoms out. What am I missing? Is the issue actually inside the transmission?

Thanks for any and all help.

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  • 1 month later...
bellarmine Apprentice

bellarmine

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Hi, do you still need help with your Bayou 300?  I have the identical machine, 2x4 tough shaft driven ATV love it.  I have the paper service manual, which you can also download here if you have 10 posts. 

Have you checked the clutch adjustment bolt near the oil sight gauge?  Can help with the shifting.  Also how about the reverse lockout knob?  Might have something to do with the reverse-neutral-1st gear shifting.

About your machine, what's the history, was working fine before, is it running currently?  At risk of being obvious, it is hard to shift at a stand still, best if it is running and moving.  I can check my shop manual for shift adjustment procedures.

Just some ideas, let me know if I can further assist.

Bellarmine

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steve-in-ga Newbie

steve-in-ga

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Thanks for replying.  I ended up putting it all back together.  I think it's in the bottom end and I'll just live with it for now. I have the service manual and did the clutch adjustment procedure and checked the reverse lockout.  The machine has done this since I've owned it.  My father purchased it used back in the 80's.  He gave it to me and purchased a new one about 15 years ago.  Finally had some time to look at it.  Shifts fine while moving.  The issue is from a stand still only.

Steve

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bellarmine Apprentice

bellarmine

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You're welcome Steve.  I have the official 1986 Kawasaki manual if that makes any difference, has lots of photographs of checks for the shift mechanism, haven't seen the one on here yet so can't comment on what is in it.  I looked in my own manual perhaps you could rotate the shift star gear, so the 1st gear peg is maybe at the 5th gear position?  Or the shift drum is worn, which as you say is in the bottom end.  I imagine the shift foot lever is not hitting the footpeg lol.......:o)  Sorry I couldn't be more help, glad it's working for you after a fashion at least.  I've had my 300 Bayou since my Dad bought it new in '86, first machine I learned to drive, fun pretty and easy to work on.  Cheers Steve!~  Bellarmine

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