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Mule jumps out of forward gear

Will

By Will
in Kawasaki UTV SxS Forum

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Will Newbie

Will

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I just bought a 1994 Mule KAF450 b-1 and when I got it home found that it popped out of forward gear. I'm waiting for a manual to help troubleshoot it but think that the cause may be the shifting dogs on the shuttle shifter and the forward gear are rounded off. Anyone had any experience with this type problem? I'm not sure if those parts are still available and if not may try to weld the parts and reshape them to rebuild the dogs.

Thanks...

Will

  • 1 month later...
4 dog knight Rookie

4 dog knight

Posted
Posted

Will,

I went thru a similar predicament, but mine was a broken internal case where the shifter shaft went thru the top of the case. I tried welding it but that didn't work because the hole was too elongated. If I had access to a milling machine it could've been bored straight and had a bushing inserted. My gears were in fine shape...it was just not able to shift into place due to the sloppy shaft. One other critical issue is that you get the idle down below 900 RPM or it won't want to drop into gear. The driven clutch is spinning over pretty fast to slide those gears into place if the idle is too high. These things will idle down to nothing if the carb is clean, etc. You may adjust the shifter cable to put more pressure on the cable. Unfortunately, it "pushes" the cable into forward, while pulling it into reverse. You can adjust it to a point where it won't clear the nuetral notch in the dashboard if you go too far. It also won't start, as it needs to sense the nuetral shifter position. I did have to replace my cable, as it was too wippy and wouldn't push the shifter shaft into the proper position.

Good Luck!

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