hi guys I have a 92 klf300b 2x4 bayou with a problem. I have reverse 1st and 2nd gear, but when I am in 3rd-5th and get higher in the RPM's its like it pops out of gear I loose all power to the rear, and I get a ratcheting kind of sound coming from the clutch cover area. I replaced the centrifugal and replaced the friction plates in the secondary clutch and have played with the adjustment screw and followed the procedure as described in the Clymler manual. I have also already split the case and changed all the components in the transmission, and still have the problem. I am suspecting maybe the clutch springs, but I'm not sure they are bad as they are still in the serviceable rage in the manual. I have gotten the bike to fail and start making the ratchet noise turned the motor off and pushed it in the garage without spinning the rear tires, took the clutch cover off to check if the shift drum position was firmly in gear, and it was. also I should note I can shift while it is making the noise, and it shifts fine all the way to neutral. then the noise stops. not sure what s slipping clutch sounds like. could use some help.
thanks joe

 

well I figured it out, the drive shaft was wrong, it was a shaft for a 86-88 bayou 300 mine is a 92. the 86-88 shaft is 3/4'' give or take shorter than the 89 and newer shafts. from what I can tell the splines were barely catching on the front of the drive shaft, causing it to skip under higher pressure. I put the correct drive shaft in and it will climb hills in any gear. just wanted to complete the thread and hope it might help someone in the future.

joe

 

Glad you figured it out, Joe. You have been very resourceful.

I have found many many parts for the Bayou 300 that are different for
the first year (86) and other A models, let alone the B's and C's. I
learned the hard way with some of them.

 

thanks i combed the web looking for someone with the same problem,but couldn't find anything. while trouble shooting i had the front bevel gear housing off. with the rear axle jacked up i was spinning the rear tire and feeling for any slippage maybe from the rear end. with one hand on the "ball joint" on the drive shaft i could feel the shaft spinning in my hand until i would pull slightly forward on the shaft and it would stop spinning. that's when i put the front bevel gear housing back on and started measuring. the splines on the front of the drive shaft were only engaging the output shaft by about a 1/16th of an inch.
like i said i hope this helps someone in the future.
thanks
joe