Well I developed a problem this weekend riding and I'm looking for opinion/thoughts. I was stuck in a mudhole, already in 4x4 (low) I pulled the Diff lock and then accelerated (spinning) I was hung up on the skid trying to climb out of the mudhole. Didn't look at the speedo but would guess wheels were doing 30mph then all of a sudden a horrible grinding noise in the transmission erupted. I winched it out, found that in 4x4 High seemed fine, going into low in 4x4 the noise and slipping returns. The front diffy does not seem to engage at all, sits and clicks but doesn't catch. Driving in 2x is fine accept upon letting off the gas, a lighter grinding noise starts.

I found the thread here about Shift linkage adjust, so I'll try that tonight.

I dropped the motor oil, didn't see any metal. Check the front diffy, no metal or missing teeth there.
I have noticed the shifter getting clunky and difficult.
I guess its possible while I had all tires spinning 30mph, the front could have suddenly grabbed dirt and spun out the front diffy, or its also possible I partially let go of the lock lever and it slipped out and ground something. Is it bad to let go of the lock while spinning at high speed with little or no traction?

Any thoughts, opinions? Who's the tranny guy around here? HELP!

 

check your shifter where it goes into you motor... mine came loose and it sarted to do what you are discribing? was the tires locked?

 

no tire lock, just jumping gears. I'll check that, I guess I need to check motor mounts too. Have you had loose motor mounts?

 

IMO, your starting point should be, as KAW650 said, check the shift linkage adjustment, and security. HOPEFULLY that is all it is, an adjustment. GOOD LUCK!!!!!

 

never seen loose engine mounts on any of my Kawis.

 

Thanks ALOT! FIXED! I tightened the shaft spline(a good full turn loose) and adjusted the linkage (1 1/2 turns in) and did the trick.
This forum RULES! [img]i/expressions/face-icon-small-happy.gif[/img]

 

THIS forum's MEMBERS rule. There are a lot of sharp folks on here.....................................
Glad we could help!

 

yeah, forum MEMBERS rule!!! In just the 2 months I've been here, forum members have probably saved me from hundreds$$$ in shop labor.

 

Your gear adjustment now needs to be fine tuned... it will take about 7-8 rides before you to do that and recheck the spline before that. I had to tighen my spline after the 3rd time out but mine was looser than yours. I also took it easy on mine afterwards until I had the final adjustment done.

 

What do you mean "gear adjustment"? more linkage adjusting? BTW have you adjusted your shifter height too?