Clutch problem on Bayou 300

[Jee]

Hello,

I am rebuilding the clutches on my bayou and on the secondary clutch when I mount it together (the pressure plate and the discs) it fits fine without any gap but when I slip the assy on the support which got the serration(holes) all around for the tabbed disc. there is a gap( the plates and discs can move). And once on the support how do I hold it from turning to torque the nut? The manual says to use a penny between the secondary and primary clutch but the shaft for the secondary clutch is still turning. Plse help.

Jee

[RCW]

Remove the cover plate on the disk clutch assembly and count your disks and steels, also make sure the first plate in the cage is in the right way and not reversed.

You can go to Kawasaki.com and follow the links to the parts diagrams to get a count and order on the clutch assembly.

The penny in the gears will definitely hold the assembly from turning if the clutch assembly is properly installed.

[Jee]

Yes the penny will prevent the assy from turning but the center shaft of the secondary clutch will still turn. I guess the primary clutch would be locked though. but how do I do to lock the shaft of the secondary clutch?

If you look at attachment I have 5 discs 13088, 4 discs 13089. When they are all mounted between 13187 and 13087 there is no loose between the discs but when I insert the assy in 13095 then the recess on 13087 contact the bottom of 13095 that creates a loose for the discs. hope that helps explain it. Plse help.

[Jee]

Hello again,

All the disks are on the proper order, Do not know what I am doing wrong. Same for the shaft, When I dismantled everything the transmission was in neutral Can it be that for the secondary clutch shaft?
thanks for the help

Jee

[kawracr]

Make sure the tabs on the outer cover is indexed properly on the inner hub. It will only go on 1 way. I always pull back on the bosses that the springs bolt onto to make sure everything is indexed correctly. If it is not & you tighten things down you will break the inner hub.

[RCW]

You want the transmission in gear and the drive wheels locked, the cover indexed to the cage, and the penny between the gears when you tighten the assembly.

However, that is not your problem. Something is not properly aligned. If it is not as simple as the bearing housing not being properly indexed, pull it all out and get it up on the bench and dry fit everything to look at how it goes together with the springs out of the way. If there is a wear ridge on one or more of the slots in the cage (main clutch housing), they can lock up one of the frictions or steels and keep it from compressing them. A flat file will make short work of any roughness, just do not over do the filing.

[Jee]

Hello Again gang,

Really sorry to bother you again but It just does not work out...
IT seems that the serrated plate where the disks slid onto has a small flange
at the end that contact the interior of the clutch cage creating the loose I am talking about. When the disks are slid on the serrated plate and the other pressure plate is put on, there is no play until I put the assy in the cage. As well, I put the ATV in gear to try tightening the nut and it seems like shaft are flexing as it still wants to turn but becomes harder( that is with primary clutch temporarily installed and a penny wedged between gear.) I am a bit afraid to break something up. Help again.

[Jee]

Hello I rebuild everything and adjusted the clutch, everything seems to be ok but my shifter does not come back to the neutral position wether I shift up or down, any suggestion?

[99prairie400]

There is a return spring on the shifter shaft that rests on a small peg. it is located behind the secondary clutch and is quite difficult to see while installing the rest of the stuff. The spring could have not popped over the peg and now isn't pulling your shifter back into position.