As noted in my initial post, I bought 2 basket case '97 Kawi Prairie 400 4x4's. I've got enough parts between them to make one good one, and that's where I'm headed.
They both sat outside for years. Got the carb cleaned out of atv#1, wiring straightened out, etc. Now, the engine runs good, has enough power, a bit tough to get started, probably still some crud in there that's gotta work it's way out. No bigger. Just takes some fiddling with the choke to keep it running until it warms up.

The problem is, no matter what gear, Rev, Low, High, whatever, when I give it throttle, the transmission/output bevels act like they're skipping for a turn, then try to engage, etc.
If I ease into the throttle, I can get it to 'lock up' and it drives around just fine...until I give it too much power and the "whatever" starts skipping again.
With the engine off, I put the transmission in LOW, shove a screwdriver in the holes of the secondary and turn it around. Eventually it'll get to a point where it 'skips' and it sounds just like it does when it skips with the engine running (albiet only one skip at a time).

I swapped out all of the gears, the chain, shafts and counter-shafts from atv#2 transmission, converter, clutch, belt, etc., everything just short of replacing the output box on the left side of the engine and the drive shafts, etc. I'll do that tomorrow. I looked at that output box and it's got a spring loaded slip shaft of some sort that probably performs the function of letting the front/rear slip once in awhile (eg. when it's stuck), but if that's the case, then the one that is on there is complete shot. I can stick a screwdriver in there and manually move that front slip collar part away from the bevel gear with a lot of effort, which would lead me to believe that the part is good. But the way it operates, or looks like it operates also leads me to think that it's the part that is making the noise and slipping.

Yes, I did search the forums here using the search term "Prairie" and "400", one at a time. The only thread that came up that was halfway close to what I'm experiencing is
https://atvconnection.com/forums/kaw...ing-gears.html

Thinking I'm going to make a quicky video tomorrow to show what's going on.

 

I owned a Praire 300 some years back and it was a great machine. I found a website that helped me with any Kawasaki issues I had, and they offered many tips to improve the performance of stock machines. It is called "Nyrok ATV website" and they used to be Kawasaki specialists. I have seen there web site recently but haven't been on it in a while now. You might check there. A parts blowup may make things easier for people to see what issues your having...pictures can equal a thousand words!!

 

I've found a parts blow up for it at KawasakiPartsHouse.com.

I swapped out the output bevel housing thing with my 'spare', but forgot to install the front drive shaft in the process. The spring loaded collar is a bit tighter on this one vs. the other one that slips, but not by much. And no, I don't have a quantifiable numbers as far as torque or leverage or anything. It just feels a bit tighter.
Problem with the skipping went away. Don't know if it was the output bevel housing thing or the fact that the front axle isn't connected.
Either way, I'll reinstall the front drive shaft when I change the oil again.

 

.



i have the same problem going on right now, any ideas?