1989 Bayou 220 shifting problem -help

Richardm · 08-18-2008

I need some help. I have a 1989 Bayou 220 with a shifting problem. It does not want to lock into first gear and the shift lever has to be lifted many times before it will go into first gear but even then, I am still not getting a "Click" like usual. Once there, it shifts into other gears fine and will click into each other gear. Reverse works fine as well. Any ideas??? Thanks

RCW · 08-18-2008

Log in to Kawasaki.com and go to the parts diagrams for your machine. There are two diagrams that you want to look at, the first is the gear change mechanism, and the second is the change drum/shift fork.

What you want to pay attention to is how the shift lever actuates a cam that rolls the shift drum. I suspect your problem is the spring that holds the change position lever to the gear change drum cam, or the bolt that holds the cam to the drum is loose. Either of the three rollers that index the change cam can be the problem too, but not likely if you can shift and hold all the other gears.

Take your service/repair manual and go to the section on the transmission and shift mechanism and you will find that it is not a difficult fix. Do not attempt it without the manual.

Richardm · 08-18-2008

Thanks very much for your suggestion. I am reasonably handy with working on stuff like this but have never had to spin a wrench on this yet. I need to pick up a workshop manual as you suggested, is there one that you would recommend? and also, should I remove the engine to work on it or can it be done on the frame? Is there any special tools required for this type of repair?
Thanks a million.

valerie811 · 08-18-2008

I would look at your shifting fork.

Richardm · 08-18-2008

Thanks, I need a workshop repair manual, would you recommend a factory or aftermarket?

RCW · 08-19-2008

I would select the factory manual over the aftermarket version, but both are good. If you call the number in the ad at the top and give them your member id, you will get a discount, and it is a good way to keep this forum going.

Richardm · 08-19-2008

Thanks, will do

08-18-2008	#1 (permalink)
Richardm Newbie Join Date: Aug 2008 Posts: 5	1989 Bayou 220 shifting problem -help I need some help. I have a 1989 Bayou 220 with a shifting problem. It does not want to lock into first gear and the shift lever has to be lifted many times before it will go into first gear but even then, I am still not getting a "Click" like usual. Once there, it shifts into other gears fine and will click into each other gear. Reverse works fine as well. Any ideas??? Thanks

08-18-2008	#2 (permalink)
RCW Wants better weather! BTK Expert Join Date: Nov 2007 Location: Oregon, Chile, Alberta, Texas Posts: 769	Log in to Kawasaki.com and go to the parts diagrams for your machine. There are two diagrams that you want to look at, the first is the gear change mechanism, and the second is the change drum/shift fork. What you want to pay attention to is how the shift lever actuates a cam that rolls the shift drum. I suspect your problem is the spring that holds the change position lever to the gear change drum cam, or the bolt that holds the cam to the drum is loose. Either of the three rollers that index the change cam can be the problem too, but not likely if you can shift and hold all the other gears. Take your service/repair manual and go to the section on the transmission and shift mechanism and you will find that it is not a difficult fix. Do not attempt it without the manual. __________________ 2008 3010 Trans4X4 Diesel Mule 2008 JD XUV 850 Diesel 1979 XS650 Yamaha New DR-Z400S

08-18-2008	#3 (permalink)
Richardm Newbie Join Date: Aug 2008 Posts: 5	1989 Bayou Thanks very much for your suggestion. I am reasonably handy with working on stuff like this but have never had to spin a wrench on this yet. I need to pick up a workshop manual as you suggested, is there one that you would recommend? and also, should I remove the engine to work on it or can it be done on the frame? Is there any special tools required for this type of repair? Thanks a million.

08-19-2008	#6 (permalink)
RCW Wants better weather! BTK Expert Join Date: Nov 2007 Location: Oregon, Chile, Alberta, Texas Posts: 769	I would select the factory manual over the aftermarket version, but both are good. If you call the number in the ad at the top and give them your member id, you will get a discount, and it is a good way to keep this forum going. __________________ 2008 3010 Trans4X4 Diesel Mule 2008 JD XUV 850 Diesel 1979 XS650 Yamaha New DR-Z400S

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08-18-2008	#4 (permalink)
valerie811 Newbie Join Date: Aug 2008 Posts: 4	I would look at your shifting fork.

08-18-2008	#5 (permalink)
Richardm Newbie Join Date: Aug 2008 Posts: 5	Thanks, I need a workshop repair manual, would you recommend a factory or aftermarket?

08-19-2008	#7 (permalink)
Richardm Newbie Join Date: Aug 2008 Posts: 5	Thanks, will do

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