question about clutch adjustment on bayou - Kawasaki ATV Forum
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post #1 of 3 Old 11-03-2010, 04:26 AM Thread Starter
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question about clutch adjustment on bayou

I have a bayou im working on that has been a real treat. Ive worked on this thing for weeks fixing everything it seems. Im down to the last thing and I have a question. This thing has been hard to shift for awhile, so I decided I would start taking it apart until I found the problem. Of course I tried adjusting the clutch with the 2 screws on the cover to no avail. I took the clutch cover off and noticed on the secondary clutch the nut was almost all the way off and half stripped. Lucky for me the shaft is a lot harder than the nut, so I ordered a new nut and reassembled it. I was playing around trying to adjust the bolts on the side so i was fooling with the shifter and broke the shift shaft off like a dummy. I noticed rust where the break happened so I know it was already an old wound from the years of forcing it to shift. I took a look at this shifting mechanism on the inside because all of the manuals/online info says how to adjust the clutch but doesnt really explain what each bolt does. The instructions in my manuals and the ones I have found online all say to fool with only the top screw. I dont like the instruction of turning it counterclockwise till hard then going clockwise till hard to adjust a clutch. So from looking at the inside i think it looks like the top bolt when turned counter clockwise adjust how close to the release mechanism is to the clutch. The bottom screw has like a concentric shaft that it looks to me like it adjust how far the release mechanism will push the clutch in. The books do not cover what to do with this bottom bolt and was wondering if anybody knew. Also, why do you guys think that bolt came loose? I was looking and it doesnt seem that the step on the shaft comes out far enough, looks maybe 1/100 inch low. I plan to torque it to spec and make it filthy with locktite unless you guys know another trick. I should have a new gasket and shaft this weekend but I dont want to ruin them so any help would be appreciated.
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post #2 of 3 Old 12-01-2010, 10:36 PM
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The bottom adjuster is for the clutch release pivot, and my manual has the adjustment procedure. Check your message inbox for a link Im sending you!
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post #3 of 3 Old 05-04-2013, 10:07 PM
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Looking for the proper clutch adjustment procedure as well

I have a 91 Bayou 300 4x4 and I cannot find ANY information on how to adjust the bottom clutch adjustment screw-

And, I have heard 2 versions so far on adjusting the top screw:
version 1 -CW until tension then back off a it and lock it down.
version 2-CW until tension then CCW until tension then lock it down.

Can anyone tell me the correct adjustment for both the upper and lower
clutch adjustment screws
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