I sure hope there are people here smarter than myself, well there has to be.
I have installed a new clutch kit and springs in my Bayou 300, since the install I can not get it to engage. I have taken it apart so many time and check the install that I can do it in my sleep backwards with both hands tied behind my brain. Yeah it's been that many times.
I have adjusted the clutch after replacing the cover and I can feel the clutch changing to reverse and the upwards gears but it will not move. Yes I have released the brakes. Seriously I am going crazy trying to figures this out, PLEASE SOMEONE HELP!

 

You are sure it is the secondary clutch that was faulty, not the centrifugal one. Have you read this post? "94 Kawasaki bayou 300 4x4 clutch issues" I can't believe you can get an extra plate in a clutch, so the possibility is there are some faulty new clutch packs out there, (not made thick enough) or Kawasaki used two different clutches and you have bought parts for the wrong one. I know Honda made two different clutch packs for the 350, one having more plates than the other.

 

When reassembling my clutch stack, I discovered that if the stack doesn't seat properly, you get NOTHING. Make sure the stack seats fully on the center hub AND the base. Otherwise, it cannot tighten up if it doesn't sit on the base properly. You have to rotate the 4 spring posts until you find the exact one where it drops down on the base splines.

I know this is an old post, but maybe it will help someone who is researching the same problem.