Bayou 300 4x4 Clutch Adjust and Shifting Issue Fix
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- เผยแพร่เมื่อ 8 ก.ย. 2024
- This video started with trying to fix a shifting issue on my 1998 Kawasaki Bayou 300 4x4, where I was stuck in neutral, then reverse. It turned into me not understanding how the shift mechanisms work nor the adjustments on the clutch. The engineer in me needed to know how it all interacted with each other so here is an ALL INCLUSIVE video.
Sorry for the length, to help out, here is a timeline of activities. Please subscribe and give a thumbs up if this helped you out!
The issue: 4:00
Clutch adjustment - how it works: 8:08
Assembly: 12:48
Clutch adjustment - how it works, mid assembly: 16:20
Shifter and component schematic: 19:58Torque specs: 20:42
How shifting works with spring: 21:09
Other components: 22:44
Clutch release mechanism: 24:33
Clutch release adjustment procedure after install: 25:20
Clutch adjust procedure: 25:28
Clutch adjust procedure on quad: 28:08
More detailed discussions would best be had at the facebook group: / 1440309449332366
This is like one of those videos I'll just leave playing in the background at work to relax
Lol, you have some strange while noise my friend :p
This is the first video of yours that I've watched. I just want to say it's absolutely brilliant, you have a fantastic way of explaining and showing how these parts operate. You're a real credit to TH-cam. Thanks for sharing your knowledge!
Thank you for that very sincere comment, it is much appreciated! I'm truly glad to help, thank you for providing a comment that gives me motivation to make another one.
This was hugely helpful, thank you! This is a complicated mechanism and even with the manual I'm not sure I would have understood it as clearly without the help of your video.
Thanks for the praise, much appreciated!!
Thanks a million! I had the same problem with loose clutch screws. Your video provides the much needed directions to confidently tackle the problem.
Glad I could help!
Finally someone that knows and shows everything .... Thankyou very much.
That's a compliment if I had ever heard one, thank you!
Awesome video man finally somebody who knows how to adjust the bottom screw. Thx man
Thank! I hear ya! I looked everywhere for details on it and got frustrated enough to pick it apart and explain in a few different ways. Glad it helped you understand it all!
Thanks for posting this. I have a 1992 300 4x4 and I was able to properly adjust the clutch after watching this. I basically turned the upper adjustment counter clockwise until the slack was taken out and then turned an extra 1/2 turn until I could feel the lower adjustment screw starting to give resistance for 1/2 of its full 360 degree turn. I then placed the lower adjustment at the mid point of the 1/2 turned that does not give any resistance. In my case the resistance while spinning it round and round was between 9 and 3 o'clock so I set it at 6 o'clock and locked it there. After i turned clockwise the upper adjustment until it got loose and just turned is counter clockwise until it rested at the point of starting to resist and locked it there. The resistance if due to the fact that the clutch springs start to be compressed so we want to take the slack off but not compress the springs early so that the clutch does not slip under full acceleration. After this adjustment, the bike shifts like new with smooth action and no binding of the gears. Once you understand how it works, it is much easier to figure out how to adjust it. I had different methods published in the Kawasaki literature so I could not understand how to adjust it properly before your post.
Glad it helped! Thanks for the comments as well!
Thank you for the adjustment on the crotch I rebuild my 400 bay you but didn't have a manual y went by like bit of video here end the wich the motor it starts up really good but it won't go forward it can go backwards 😅 but you video help me alot
@@robertolopez8146 glad I can help. I recommend you ask questions on the Facebook group, there may be something unique to the 400.
Thank you so much for this video. It helped a ton. I’m having some trouble. I was having some slipping and made some adjustments to the top screw. It was and is better. I came across this video and attempted to adjust the bottom screw. Mine just spins and spins. Everything seems to run ok just can’t get the bottom screw to get tension.
turn you top screw all the way clockwise,then counterclockwise between a 1/16 and a 1/8. snug up your lock nut. back off the lock nut on the bottom screw. turn screw left and right, fund the loosest point between left and right. lock the nut down. you to your top nut and do your book adjustment ( I my case I go all the way clockwise until it seats, then all the way counterclockwise until seat and then about a 1/16 to 1/8 clockwise. tighten the locknut) my clutches are worn
You did a killer job on this video ! Thanks.
It's comments like this that keep me making more, thanks for taking the time to comment!
Great video very helpful and good explanation of what would be a v difficult process if you didn't know how to do it
Thanks for the compliment!!
Awesome job on that video. I bought a '93 about 8 years ago and the shifter has never worked right. Now I might be able to adjust it. Thank you sir!
Thanks! Glad I could help!
I can't seem to get it right at all. And I can't even find a book on it. It is driving me crazy. By any chance do you have pictures of the clutch set up
New subscriber and getting ready to restore an old Bayou 300.
This video helped a lot!
BTW, what Shop Manual are you using and which one do you recommend?
The factory ones I find to be best but the clymer manuals will get you through. Free always seems to be the best sister turned around and you will find
@@sshawn09 Thank you!
Fantastic and detailed video, thank you!
No prob, glad I can help!
Amazing video thank you so much!!!!!!!!!!!!!
Glad to help!
Amazing video, its definitely going to help me tomorrow. I just had new cams made for my 400, but i cant get any forward gears. i suspect i have an issue similar to yours.
Awesome, I hope it works out I am unfamiliar with the 400 but relatively the clutches should be about the same
@@sshawn09 The motor is different, the oil screen for example, but the gears all look identical:-)
Nice vid i have a 2003 Kawasaki 4x4 300cc bayou . And I'm trying to find a brand new shifting Rod shaft.
The Facebook group for bayous is quite active, you might find one there for cheap
@@sshawn09 yeah I'm not looking to buy second hand when it comes to working on small engines I buy brand new. I just been looking online for a brand new one and all I find are these little pieces of crap second hand ones on eBay
A beautiful video
Thanks!
The bottom one is to adjust your loose in the shifter ant the one one top is for your push plate for the clutch
You helped me
cool comercials and great6 video
Thanks!
This video would be 1000% better if we saw it Mobile and shifting at the end.
Good recommendation, you are absolutely right. Lemme see what I can do
Can the oil pump gear be replaced with a metal one?
Sorry I'm not sure. I recommend asking on the Facebook bayou forums
Hi I have a kawasaki kef 300 1990 year. I replaced the clutch discs and the centrifugal clutch, the gears enter but the clutch slips and does not go help because I am broken
Make sure that it is adjusted as I show in the video. If that doesn't work, maybe something was assembled wrong. Are you using normal oil?
@@sshawn09 I flooded with Valwolin 10w40 4t oil. I had previously soaked the blades in oil. tomorrow I will try to regulate it somehow. And if not, I will have to dismantle it. Because if he was driving and when I replaced two new clutches, he doesn't drive, I put something wrong. But what if there's nothing wrong with that?
@@sshawn09 th-cam.com/users/shortsfOCpdjyvdnQ?feature=share this is what it looked like after assembly
I forget what it's called, but the High low clutch on my bike doesn't lock. So if I'm going up a hill it will move and I can no longer go forward. Scared the heck out of me the first time it happened. I had no idea what was wrong
Sounds like the clutches are slipping / maybe worn out. Best advice I can give is to ask the question on a facebook forum, the bayous have a good one, facebook.com/groups/1440309449332366
This is a great video. Do you have anything on replacing the reverse lever spring? I have a 2008 Bayou 250 and when I use the reverse cable, it stays engaged. I understand there is a internal spring on the lever. Anything on that spring replacement?
I haven't had the time to have a look at that yet, sorry. There is a Facebook group I'm a part of that I'm sure someone can give you some tips. Shout again if you can't find it, I'll look it up.
Mine is doing the exact same thing. When I try to adjust. It binds everything up and pushes against the case.
Ooof, sounds like something loose in the basket?
Where did you find the manual
@@James-h3m search clymer bayou 300
Did it fix the problem. You didn't show in the video.
Hollou Rossia Kineshma 👍🖐️🖐️🖐️🖐️
When I took my cover off I found a washer in the bottom of it. Would it by chance go over the shifter mechanism
Take a pic and send? sshawn09@hotmail.com
@@sshawn09 I believe it goes behind the shifter after watching your video more I seen it in the book you had. Appreciate the video! When should a guy replace the friction clutch plates?
@@AlexLopez-tk1ft no prob. Good question,, I'm not too much of an expert on it but I'd think when you slip while at stable throttle then hammer it.
@@sshawn09 I sent you an email
@sshawn09 do you have to reset the adjustment screws each time when you remove the case off the motor and put it back on
sshawn09 : THANK YOU SIR FOR THIS AWESOME VIDEO . IM NEW AT THIS ,HOPING BAYOU 220A IS THE SAME ISSUE . WHAT IS YOUR MANUAL YOU HAVE HERE ? AGAIN THANKS & BEST BLESSINGS .
No problem! That manual is a clymer