By
Machias_Mike
Hi there!
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.
https://www.quadcrazy.com/atvforum/topic/14281-1994-bayou-220-neutral-safety-switch/
Here goes!
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.
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