i recently put a new top end and oil pump in my 97' lakota. i had to remove the clutches to install the oil pump. now i cant seem to adjust the clutch, it either will jump forward and stall out when i put it in gear or it will slip and not move. ive tried adjusting it about 10 times and cant get any good results. it will run great if when i put it in first gear i hold up on the shifter and release it slow as i take off -like a manual clutch - am i doing damage by doing this?
thanks!

 

You may have one or more warped steel discs preventing the secondary clutch from releasing properly. (The primary, centrifugal clutch operation should not be affected by removal and reinstallation.)

Assuming the Lakota clutch setup is like the Bayou's, you have two adjustment screws--an upper one and a lower one, both accessible behind the adjustment cover.

The upper adjustment screw controls the engagement. After loosening the locknut, move the screw clockwise until resistance is felt, then counterclockwise until resistance is felt. Cinching it down at that point adjusts a properly-functioning disk clutch correctly; if memory serves, too far counterclockwise, the clutch won't engage; too far clockwise, it won't release.

The lower adjustment screw positions the release mechanism; a one-time adjustment. The trick is to move the eccentric pin on the inside of this screw shaft as close to the upper adjusting screw as possible, centering the slot the pin rides in. This point can be approximated without removing the right case cover by loosening the locknut, and setting the lower adjusting screw halfway between the clockwise and counterclockwise resistance points.

The service manual has some pretty good illustrations; maybe the exploded parts diagram in the parts catalog at www.buykawasaki.com will help clarify the clutch adjustment procedure if you don't have a manual.

That's all I know about adjusting a Kawasaki clutch; from the symptoms you describe, I'd check the clutch release mechanism; also, I'd pull the four secondary clutch bolts, disassemble the disks, and check the flatness of the metal clutch plates on a flat surface, as well as the condition of the fiber disks. Replace the metal disks if they aren't true; if you need to replace the fiber disks, I found the RAD racing clutch disks and extra-heavy clutch springs from Recreation Unlimited work well. Good luck!

Tree Farmer

 

your dead nuts on the adjustment method for the secondary. this is the method i used and its straight from the service manual.i dont recall any other adjustment . i will have to check it out when i get home. i do know that the first owner had to have the clutch replaced when it was almost brand new and that the fingers on the basket and the first steel plate were wore like they had rubbed on somthing. i dont think that the person that replaced it knew any more about it than i do because when i removed the cover i found one of the 4 bolts that hold the plates in the basket loose, and they removed the oil screen and didnt replace it.
TREEFARMER- thanks for all of your responses - i have read many answers to many questions from you and you seem quite knowlagable and VERY WILLING TO HELP fellow atv'ers. heres to ya!

 

Thanks, mster; I believe I've learned a lot more than I've "taught" on the Forum, but if I think I can contribute to the discussion, I'm glad to offer my best effort. To me, the primary purpose of the Forum is exchanging knowledge, experience, and opinions, while respecting those of others (maybe not the majority view!).

I learned at least one valuable lesson on clutch work from the Forum: GET AN IMPACT WRENCH! A poster, who had grenaded his clutch basket when his hand tools slipped, advised me so when I was struggling with my own Bayou's clutch; then, a Sears 7-amp electrical impact wrench became my birthday present that year; my life has been much happier since!

Best wishes,

Tree Farmer

 

tree farmer- could that be the cause of my problems? the electric impact? without the use of the"special tool"to hold the gears from moving you cant even get the darn thing off,and you cant properly torque the bolts. i just put the impact on till the bolt stopped turning.(over tight?)
also i could have over torqed the 4bolts that hold the plates in the basket would that cause these symptoms? thanks again