I have a 2000 Prairie 400. Had since new. 4500 miles or so.

The last few years when riding in snow I've noticed the shift lever becomes hard to operate. Seems to be related to cold temps. The more snow I ride in, the worse it gets. It seems to be the shifter itself and not the little button you push for low or reverse because the button seems to operate fine.

This year is worse.

I just took it from the 50 degree garage outside to wash it. I suppose it was 35 or so outside.

The shifter worked ok before washing but would barely shift after.

When I let the machine idle for 5 minutes or so, the shifter freed up enough to go to different gears but it was sluggish.

Any ideas?

 

Ok, removed the lever, housing. Easy.

Disassembled.

Really simple inside. Basically, the housing contains a plunger which moves back and forth if the shift lever button is depressed.

The plunger has two square keys about 1.5" long each that just drop into a few holes in the plunger.

It was surprisingly clean in the housing but, the big double lipped o-ring that seals the housing was pretty dried out as far as grease. I pulled that oring out and cleaned the grooves in the housing, and the grooves in the double lip o-ring, then regreased everything with waterproof grease before reassembly.

I did remove those 2 square keys and now there is no need to press the shift lever rubber button before going into low or reverse. Haven't ridden it yet but guessing it will stay in gear just fine, only be careful not to shift into L or R without stopping first.

I'll let you know if this fixes my problem. It works smoother on the trailer.

 

Well, pat myself on the back, ha ha.

I test drove the machine yesterday and it shifted great. Haven't ridden it in freezing temps or snow but have confidence the shifting will still be good.

 

I am a 1st time owner of an ATV, bought a used 2001 Kawasaki Prairie 400. My question for you, Mr Summit is how did you remove the shifter and take out the 2 keys for the button that allows shifting into low and reverse. Had an issue tonight with the shifter being stuck in low gear on my son's truck. Did finally get it to shift after a couple tries. Any help with doing what you did to your Prairie would be greatly appreciated.
Thanks
Dfab-one

 

iirc, remove a few screws holding the plastic cover which has a label indicating the gear you are in.

remove the connection between the shift lever and engine.

Remove two bolts hoding the shift lever arm housing to the frame.

On the backside of that housing, remove the large nut.

Carefully disassemble the unit. Prettty simple inside.