'03 Kawasaki Prairie 300 Stuck in Gear

[alexwv1863]

I believe the Kawasaki is either an '03 or '04. Green automatic with shifter on the right side. Rear differential was bad, so I replaced it with another. The 4 wheeler rolled in neutral when I parked it in the shop to work on. Took old diff off and replaced it with another one. The diff I put on, turned before I put it on the bike. Once I put it on the bike, the rear end wouldn't move at all. It's like it's stuck in gear. Bike is still in neutral. I've tried rocking the bike while trying to put it in high, won't budge. Can anyone tell me of something to check or try? I haven't opened up the transmission case yet to see what's going on. What should I be looking for? 

[Gwbarm]

So once you hooked up the driveshaft it wouldnt turn, but both engine and differential was turning freely before you hooked up the driveshaft.

[alexwv1863]

Yes, we pushed the bike into the workshop. I don't know if I twisted on the drive shaft after the rear end was off, or what. I've been working on the bike off and on for a few weeks now, so I can't remember exactly if I did something and just don't remember. I do know that the diff I put on turns when not attached to the drive shaft. I've taken it off twice now because the first time I tried putting it on, there's a spring that goes from the pinion gear to the inside of the drive shaft, well I smashed that sucker all up. I took the rear end back off and put another spring in there. I first thought maybe that was the problem and with the first one smashed, it bound it up or didn't provide the right spring to allow with shifting gears. It might sound silly, but I was just trying to troubleshoot.

[Mech]

Well my first thought was that the brakes were locked up, but you are quite certain that the diff and axle turns when the drive shaft's disconnected, but locks up when the driveshafts on..  right ?

So, if you disconnect the driveshaft from the diff, does the driveshaft turn the engine's output shaft ?

Edited November 9, 2024 by Mech

[alexwv1863]

I can't remember if I check the output shaft or not. I've had the rest end off twice. I'm pretty sure I checked it the first time. The only other things I know to do is take the cover off the transmission gears on the side of the engine. It's probably called something else. It also won't go into gear using the gear shift selector. With this bike, I wouldn't think it would have to be running before you could shift into high or low. 

[Mech]

Ok, you need to verify one thing at a time and be methodical figuring out where the problem is. It was all working, it should still work.

So.. Is this bike 2wd or 4wd ? Are you trying to turn the wheels by hand, and with the wheels off the ground, or are you trying it by attempting to push the bike forwards?

It's possible if it's 4wd and the new diff is the wrong ratio that the gears are binding up making it hard to shift gears, and it can also cause a lot of fighting between the front and read wheels making it hard to push/move. If it's jacked up so all the wheels are off the ground then there won't be any fighting and the individual wheels will turn.

If you are trying it jacked up then I'd do more testing before I pulled the side cover off. It rolled into the workshop working ok, nothing inside the box should have got damaged.

Since it was rolling in neutral when you moved it into the workshop..  I'd pull the back end again and turn the driveshaft to check whether it's something in the diff or something in the box first.