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4x4 Shift Linkage for Old Cat ATVs

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6.4K views 7 replies 3 participants last post by  Matt193  
#1 ·
I have a '99 300 4x4 with IRS. I like the machine except for the 4x4 engagement system. IMHO, the cable-actuated 4x4 engagement method on these old machines is one of the worst designs I've ever seen. I don't think it's ever worked properly, even after a fully rebuilt differential with a brand new cable.

My questions are:
(1) Do the slightly newer 2002+ 4x4 shift mechanisms work with a lever, instead of a cable?
(2) If (1) is YES, then is it possible to convert the cable system to a lever system? I think, yet am not certain, that the chassis from '98 to at least '04 is the same, yes?
 
#2 ·
I have an 05 300 4x4 that has a lever to shift in/out of 4x4. It's the typical shift lever located on the left front fender like other atv's from that era. 98-05 chassis' are close however the front diffs change in 2002. 2002 and up the lever is on top of diff. I can't tell from part illustrations where the 98-01 shifts in/out of 4x4 on the diff. Also on the 2002 and up there is a bracket welded on the frame where main shift lever pivots to diff.
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#5 ·
Nope, they used the same diff but went to a shift arm. I have an extended arm that I had on mine that I changed out when I sold it. I changed it out for a stock one because the extension isn't very pretty. I can take a pic of it for you if you want to see what that looks like.
 
#6 ·
You can try finding a 0436-310 shift lever kit which includes everything you need to swap it over, but they've been long discontinued and are probably all long gone. Edit: Actually there's a bunch of them on ebay for really cheap! I'd go that route for sure!
 
#7 ·
Matt193, you rock!
Do I understand this correctly; are you stating that 0436-310 is a complete kit which allows one to convert their pre '01 4x4 from a cable actuated shifter to the'01+ lever actuated 4x4 shifter?
Is that's true, do I cut a hole in the plastic above the left knee where the new shift handle is located? I can't find a copy of the 0436-310 instructions so I could read them.
Thanks!
 
#8 ·
Yep, it has everything you need. This kit is actually to add a 4x4 shifter on the 250 because it was sold as full time 4x4, but it works just the same to convert from cable shift. I put one on years ago and if you get one that has the instructions with it (probably folded up in the hardware pack) it comes with a template that you place on the lower left fender that will show you where to drill the holes. I'm pretty sure you need a 1/2" drill bit for the screws that hold the mount to the fender and a 3/4" or 7/8" for the lever pass through. The shifter location will be in the same area as all '01 and newer units. If you don't get the instructions, I'm sure a dealer would be able to print out a copy for you.