Today, I show you how to Replace the secondary clutch in a 1993 Kawasaki KLF400 Bayou

Dino’s Tinker Shed, S2-Ep29.
I show you how to Replace the secondary clutch in a 1993 Kawasaki KLF400 Bayou
Today I show you how to replace the secondary clutch in a 1993 Kawasaki Bayou 400. This is not a difficult project to do but it does take some time to get done and does require a few specialized tools to do it right.
I had been noticing some clutch slippage in higher gears on my 1993 Bayou for some time now, it has recently been getting worse and was even impacting the lower gears as well, so I had to address the issue. I had already changed out the primary centrifugal clutch and this did not seem to help much so I ordered a secondary clutch pack and got to work.
For those who do not know, the KLF400 bayou uses a semi-automatic twin clutch set up for its clutching needs, it uses a primary centrifugal style clutch (like a big chainsaw clutch) for when the bike comes to a stop and idles, and a more traditional style multi disk wet clutch actuated by the toe shifter for gear changes.
Clutches are consumable items and after 29 years of use it is obviously time to change out the clutch pack for a fresh unit.
I have included time codes so you can skip around to different parts of the video if you are doing the same project and I hope the tutorial helps you out.
TIME CODES:
00:00- Cold Opening
01:21- Introduction
01:42- Overview of how the dual clutch works
05:06- Removing the clutch cover
12:13- Inspection of the oil screen
12:56- Cleaning of the covers matting surface
13:59- Review of clutch layout
16:07- What’s in a clutch kit?
18:37- Clutch removal
20:22- Anatomy of the secondary clutch and inspection
21:54- Disassembly of secondary clutch
23:34- Measuring the clutch springs
26:12- Measuring the old friction plates
27:05- Reassembly od secondary clutch
30:00- Re-install clutches
31:15- Installing side cover
34:02- Clutch adjustment
36:19- Adding oil and testing
37:54- Summary


MUSIC:
Intro music
Country Cue 1 by Audionautix is licensed under a Creative Commons Attribution 4.0 licence. https://creativecommons.org/licenses/...

Artist: http://audionautix.com/