tranny not right

[LaDano]

I finnally changed the shift shaft in the bayou 220 and now it won't shift into neutral or reverse. 1st is as low as it will go. My clymer came in today and I reserched it but can't find my mistake. Also it is making a nasty noise in the tranny that wasn't there before. Could I have gotten the shift drum segment pin in the wrong hole? That is the only thing I'm not a 100% on. Need Help fast, Thanx Dan

[LaDano]

nobody?

[Kilborg]

I do not know the bayou that well, but i'll try to help.

Tear everything down. get everything laid out nice in a clean area so you know what your working with...clean all the parts thouroughly as you rebuild it. Take it nice and slow, and follow the book 100%. It sounds as if you may have a overly worn shift drum, or a bent fork. There could be many other problems, but with what info you gave and what i have in front of me (nothing), its hard to say. Just tear it down and go step by step.

[LaDano]

JohnnyBlaze, I'll try to give a little more maybe it'll help. When I bought it we cranked it up and ran it in the truck, no noise just purred. Got it to a buddys house and ran it out of the truck into the back, I tore the right side down to replace the shift shaft. I've built several fords through the last 15yrs are so and usally very carefull on a unfamilar teardown. But I've goofed up before, as noted in other posts. To remove the primary and secondary clutches kawasaki has a tool that is nothing more than a gear put between the two clutch gears (wedge). I used a allen wrench that fit perfect to hold them from turning. Both nuts were so tight I had to use a hammer on a 1/2 drive breaker bar. Maybe not such a good idea but they had to come off. Now after the shift shaft was installed the fork from it does not contact the pins on the gear on the shift drum. I've taken it off and put it back together 4 times 100% by the book still have the same problem. The noise sounds like something slapping in there. Hope I gave a little better description, cause I need some bigtime help. Thanx Dan

[LaDano]

Still broke, any ideas?

[thefox]

there should be 3 return springs in there make sure that they are all in the right place and not backwards.

hope this helps, Andrew

[LaDano]

Fox, the only spring I can remember is on the gear selector roller. What is the other 2 your talking about, thanx Dan

[thefox]

go to.... http://www.buykawasaki.com/Default.asp?strContentURL=Site/VIVehicleInformation/VIepc.asp?VinNbr=&intCatalogID=2&CatalogTypeID=1&ProductTypeID=31&ModelMarketingID=68&ModelYear=1992&ModelCode=KLF220A5&SHOWVEHTABS=1

then click on " gear change Mechanism"

-Andrew