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HD6GTOM 
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Joined: 30 Nov 2009
Location: MADISON CO IA
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 Topic: 1999 Kawasaki bayou 400 clutch
Posted: 29 Mar 2021 at 6:14pm |
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Does anybody have the tools to replace the clutch on this machine, that you no longer need. Bike shop wants 500.00 labor + parts to replace grandsons clutch. I've replaced dozens of clutches in trucks and I have 2 very detailed manuals with good pictures for this machine. I cannot see why he and I cannot replace this thing. I can get the tools off Amazon, but if one of you guys have them laying around I'd rather buy them off someone who no longer needs them. Complete clutch is less than $150.00. Thanks guys. PM me with your price + shipping to 50273.
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steve(ill)
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Joined: 11 Sep 2009
Location: illinois
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Posted: 29 Mar 2021 at 7:59pm |
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Tom.... isnt this a $10. tool on Amazon ???
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Like them all, but love the "B"s.
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desertjoe
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Joined: 23 Sep 2013
Location: New mexico
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Posted: 29 Mar 2021 at 8:10pm |
I do have some of the tools needed for the Polaris ATVs ,,,I made these cause buyin them from the mfgr is very expensive,, Is it the Primary or the secondary clutch??. If it is the secondary,it is NOT pressed on or tapered so it comes off pretty easy. IF it is the Primary,,,,you will need a special size bolt to get it off because it is tapered to the engine crankshaft ,,,,and sometimes the Primary clutch can be a real bugger to break it loose. What is ATV actually doing that you think is one of the TWO clutches....???
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steve(ill)
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Posted: 29 Mar 2021 at 8:16pm |
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Like them all, but love the "B"s.
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HD6GTOM
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Joined: 30 Nov 2009
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Posted: 29 Mar 2021 at 11:16pm |
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Joe, it barely pulls itself. Starts great, runs great, has all gears but will not pull itself up the slightest slope. He says he's done both clutch adjustments, we'll see tomorrow afternoon when he is off work for the day. According to the guys at the bike shop we need 2 tools . The one pictured and another. Thanks Steve. I can order them and will if no one has some they want to get rid of. Thanks for the info guys.
Edited by HD6GTOM - 29 Mar 2021 at 11:18pm
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desertjoe
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Posted: 30 Mar 2021 at 3:28am |
Hey Tom,,,have ya'll done any trouble shooting on the ATV,,?? It may be as simple as just replacing the drive belt,,,,? When you pull the big black plastic clutch cover,,both the Drive clutch and the Driven clutch AND the belt will be visible,,,,and should tell you what the issue is and may be just a belt replacement where you do not need to remove either clutch to replace the belt. On those ATV's there is no "adjustmant" as the measurement between the two clutches is constant and is NOT suppossed to move. There is an adjustment to line up the driven clutch to the Drive clutch by adding or removing spacer washers to the driven clutch. Hope this helps,,,,,
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desertjoe
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Posted: 30 Mar 2021 at 3:39am |
Hey Tom,,,the one tool that Steve pictured is for removal of the Primary (Drive) clutch and can be "made" with a piece of 3/4" fine thread bolt stock. The other "special tool" required is the tool to dis-assemble the Primary clutch,,if you are going to rebuild the clutch,,,,IF you are going to replace the Primary clutch you won't need the high priced tool,,,,,,  IF they quoted you $150 for a new primary clutch,,,you better grab it as I've seen em run in the $300-$500 range.
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HD6GTOM
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Posted: 30 Mar 2021 at 11:02pm |
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I'm gonna have to look at it, I don't remember any plastic cover. Joe Thank you for the info. Gonna get his car fixed this weekend, might get a chance to look at it this weekend.
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desertjoe
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Posted: 31 Mar 2021 at 4:02am |
Aw Chit,,Tom,,I didn't realize I didn't mention that,,,,It is the BIG black plastic thingie that covers both the Primary and Secondary clutches and the engine and transmission. You can't miss it,,gots about 8-10 bolts to get it off,
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desertjoe
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Posted: 31 Mar 2021 at 9:10am |
Hey Tom,,,I kept thinkin on your Grandson's ATV and looked it up and it is a totally different clutch arrangement than the ones I've worked on, The good thing is,,,the clutch on your ATV has a clutch adjustment that looks to be very easy and you only have to remove 4 little ole bolts,,a 12 mm wrench and a screwdriver,,,,,,  Ahem,,,,you don't owe me nuttin, Tom,,,see'in as how I likes you,,,,,,, 
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PaulB
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Location: Rocky Ridge Md
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Posted: 31 Mar 2021 at 10:12am |
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an old JEEP would do as much or more that one of those newfangled oldfartcarts and be easer and cheaper to operate.
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If it was fun to pull in LOW gear, I could have a John Deere.
If you can't make it GO... make it SHINY
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steve(ill)
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Posted: 31 Mar 2021 at 12:25pm |
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Old jeep is fine if your not knee deep in mud... Boy has a 6 passenger POLARIS... That thing will climb a tree and go thru mud you cant walk thru.
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Like them all, but love the "B"s.
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desertjoe
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Location: New mexico
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Posted: 31 Mar 2021 at 10:11pm |
Yep,,,the UTV's, ATV's of today will make a grown man cry at the places they will take you,,,,if you got guts enough,,,and about 3 times the MPH than any Jeep will make. My 3rd Son has a Can-Am Commander with the 1000 Cc engine and 4WD , that thing is a hill crawling monster,,,,!! I DO NOT go with him any more as he gots way more guts than this old man. Never will forget one time we were going into a canyon we'd always wanted to explore and I had to get in the back,,the dang slope was so friggin steep,,,,the bad thing is having to hang onto the front when we had to come out,,,JIMMMINNY WHOOOEEEe,,I told him Then,,,you ain't ever gettin me in that thing again,,,and I ain't been,,,!!!
Edited by desertjoe - 31 Mar 2021 at 10:12pm
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