I have a 94 Kawasaki bayou 300 4x4. I just replaced the timing chain and tensioner, put new values in the head, and new primary and secondary clutches in it. The clutch was slipping before just on take off and on a incline but now it slipping on take off and even flat ground. The secondary clutch plates are very loose in the basket are they supposed to be tight or loose? How do I fix it and what did I do wrong I put everything back together exactly as it was but didn't notice if they were tight before changing them.

 

The whole pack of secondary clutch plates should be tight together but have to slide in the outer basket so are not tight on that. Did you re-set the clutch adjuster after the rebuild? The first Quad clutch I rebuilt, I didn't get the splines on the outside of the centre parts lined up when putting the four bolts back in, can't remember the symptoms, but the clutch didn't work and the back steel plate was bent, luckily the old steel plates were OK so I re-fitted one of them and made sure those splines lined up next time.

 

Are you talking about the adjustment on the outside cover? I did adjust that one with no difference. The new plates are not tight at all. It acts like I'm missing some but I took 5 disk and 4 steel plates out and put 5 disk and 4 steel plates back in

 

Yes, the adjuster is on the outside of the clutch cover.

The steel plates move along splines on the clutch centre, but some of those splines are on the back part of the centre, are the splines lined up, and is the back steel plate on them?

 

I had the same problem. I took it apart 4 times, read the walk through several times in the manual.
It would not stop slipping.
So I just added another friction plate and ive been riding for the whole season probably 40 hours so far.
Never worked better