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Transmission popping in kawasaki mule 4x4

When vehicle is in 4 wheel drive, some times there is a loud popping sound coming from somewhere under the vehicle. It can also be felt on the floorboard when it happens.

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  • 2 Answers

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Posted on Jan 02, 2017

  • 33 Answers

SOURCE: Kawasaki Ninja 4-Wheel

I have taken a lot of these power wheels apart, there are nylon gears that when the vehicle is powered forward and cannot move the teeth on the plastic gears will wear down and slip.

Here is an ebay site.
To replace the gearbox you will need to take off the axle cap and shaft washer that holds the wheel on.
Slide off the wheel.
I think this power wheel has a silver plastic housing that covers the gearboxes and axle, which means that there will be an amount of screws to take out before you can get to the guts.
Once you get to the wires on the motor you will need to cut and strip them and install the replacement
If you can, I would prefer you would crimp the wires together with a blue or Yellow **** splice, but if you do not have crimper or lugs You can use wire nuts large enough to firmly connect both wires. Then electrical tape the nuts and wires to prevent loosening by vibration. Even though these are 6 volt batteries their current is enough for wires not connected well to overheat, melt and could possibly become a fire hazard.
Ideally the wires from the replacement would be the same color as the original but if not you will want to test to see if while in forward it does go forward. If not you need to reverse the two wires. This is a headache saving measure.
Re-assemble everything making sure that the axle nut or cap goes back on Tightly to prevent the wheel from falling off during use.

Posted on Sep 27, 2008

  • 10 Answers

SOURCE: battery life

the part is called a stattor or statter but it should be a black box with raised lovers on it attached to out side of bike usually in the front with 2 or 3 wires coming from it to a plug then the wires going into the engine.Check the plug for fit and cleaness or Change that box if that doesn't work it's internal. take it to a dealer or independent and have repaired

Posted on Jan 31, 2009

  • 66 Answers

SOURCE: 1997 yamaha timberwolf 4 wheel drive only front wheel drive work

check to see if driveshaft to rear is turning.if it is, either the ring gear & pinion gear in the differential are not making good contact either from being worn, or out of alignment due to worn bearings in differential case,or both.check if axle has back & forth play in differential,indicating worn beaings. also could be worn ring gear to axle contact in differential.check for vibration in axle while in gear increasing as you give it more gas, caused from ring gear teeth slipping past teeth on axle.they would have to be replaced together. oversize wheels & tires tend to accelerate axle/ring gear contact teeth.

Posted on Feb 16, 2009

  • 2 Answers

SOURCE: 1996 Chevy 4X4 Problem with Transfer Case & Transmission?

check vaccum actuator on front diff?use vaccum gauge should be 25 to 30lbs to open had same problem 94 gmc sierra ext cabb 4x4 5.7 ordrive tranny

Posted on Mar 14, 2009

  • 434 Answers

SOURCE: 2002 Kawasaki Prairie 650

Either the switch on the handlebars isn't making contact. Or the shift motor on the front differential is broke.

Posted on Jul 07, 2009

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As far as I know the procedure should go something like this...

Stop the vehicle, engage the parking brake and if applicable, get out and turn the hubs on the front wheels from Free, to Lock.(You may not have these on a Suzuki, they may be auto-lockers)

Get back in the vehicle and put the transmission shift selector into Neutral.

If you have a manual transfer case, move the selector-shaft to 4x4-High, or 4x4-Low -- whichever is desired. Now, putting the vehicle in gear with the transfer case is sometimes somewhat difficult. As long as the vehicle's transmission is in neutral, don't worry, the gears inside the transfer case are big and beefy -- Don't be afraid to be rough -- Again as long as the transmission is in neutral. You may also have to disengage the parking brake and slightly let the vehicle roll forward or back with your foot-brake to get the Transfer case to lock into place.

Once 4x4 of the selected High, Or Low range is selected, usually indicated by the vehicle jerking slightly with a slightly loud clank/thud. Move the Transmission selector out of neutral into your desired gear (Drive if Automatic, if Manual, whichever gear you pull out from). and voila! You should now be in 4-Wheel-Drive.

To disengage 4-Wheel-Drive. Just reverse the steps.

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