In 1st, 2nd, and 3rd gear I don't notice any slippage but when I get to fourth and fifth, the engine begins to really scream when getting on the throttle. I have adjusted the clutch but the problem continues.

I don't know much about clutches and was hoping you could help. Do I need to replace a certain part of rebuild the entire clutch mechanism? How hard is the job for do it yourselfers?

thanks

 

Disclosing the machine in question would help, tealboy.

Generally, adjusting the engagement might solve your problem. If that doesn't cure things, opening the clutch cover (you'll need a new gasket; also, probably, an impact driver or impact wrench to remove the case screws) and replacing the fiber clutch disks may be in order (you may need an impact wrench if you're pulling a shaft nut).

Recommend a service manual.

Diogenes

 

I did not think it mattered since virtually all ATV's and cluthces operate similiarly, but if it helps, mine is a Kaw 300 bayou.

 

It is normal to first notice the clutch slipping in the upper gears. Changing the clutch plates is fairly simple and I would recommend replacing the drive plates as well as the friction plates.

 

Why post a question about a Kawasaki in the Honda forum?

Clutch engagement adjustment on a Bayou is easy; loosen upper clutch adjustment locknut (12mm), turn screw clockwise until you feel resistance; then, turn counterclockwise until you feel resistance. Tighten locknut without disturbing screw orientation.

You can replace clutch disks & springs without removing shaft nut. I'd recommend RAD racing fiber disks and extra-strong springs from Recreation Unlimited, about $ 50. No need to replace the metal disks if they are in good shape (not warped or burned).

You should use a new clutch case gasket when you put it back together. You may be able to remove the 8mm case screws without an impact wrench or impact driver.

Diogenes