1 st thanks for any help!!!!!
I've a 95 boyou 400 klf 4x4 that keeps popping out of 4th gear only. Seems to be alot worse if its under load, or when I am trying to run it at top speed. pops from 4th down to third,I tried to adjusting the upper clutch release and it seems to help alittle. I have never tried the lower adjusting screw because the dealer said that if I did it would mess stuff up. I do have manual on this atv, but thers no info on the adjusting screws. Or I should say what they really do. Thanks again.

 

Bump someone HELPPPPPPPPPPPPPP THANKSSSS

 

I was wondering if you had ever gotten this problem fixed. I have the same bike and the same problem. I'm really needing some help here. I've worked, worked and worked to try and figure it out and to no avail. please help.

 

If you have already adjusted the clutch release then i would have to say that there is something internally wrong with the tranny. just a guess

 

thanks alaska, that's what I thought to, so I tore the engine apart and split the cases. I had found, after very much work thatthere was only minor wear on all the parts. Did Not Make Sense. I'm really hurting for ideas now, I was hoping that maddog was still visiting forum and could tell me what fixed his. Hopefully!!!!!

 

"Minor wear" can be a real problem with cogs and gears and such in any tranny. A factory kawasaki manual may give the limits to how much these gears can be worn. After the initial break in period, gears in the tranny should literally wear only a few thousands of an inch over the life of the tranny. If you can see wear with your eye then it is most likely entirely too much wear.

 

I had check the limits on all the parts, and everything was well within tolerances from the manual. I think I may have found the problem, you will not believe!! Kawasaki Technical assistance had sent me a technical bulletin on this exact problem---all it needed was 4mm of material added to the shift detent arm, probably would've taken me 45minutes to repair. So I'm going to start putting the bike back together and do that modification. hopefully it works.

thanks for the help though!!!

 

How did you fix this? Can you please elaborate, I have the exact same problem with this bike. My dealer doesn't know how to fix it and says the Kawasaki Technical Hotline was no help. Please help!!!!

 

It was the shift spring, I did'nt fix it myself. I took it to the local repair shop and had it done. It cost me $50.00 to get it back up and runing. That was for everything new oil also, I could get some more info on what he did if you
need me to.
Just email me, I'll see what I can come up with.

 

midwest
You are right, I would'nt doubt if he used a spark plug top and put it on the spring.