SICK OF IT

[oldmutt]

I think Little-Boo hit the nail on the head. I now remember my ramp moving back and forth when I was trying to back off the jam nut on the rod. I thought about it at the time but I was lucky and mine worked the first time.
Good Luck and ride safe!

 

[stlmikie]

My guess is that he got some slack in the cable. And at the handle bar the cable cover pulled out a bit and slipped down taking up the slack leaving no adjustment. I've seen that more than once.

 

[05 old dog]

is it possible the outer hub was not lined up with the grooves in the clutch hub...ive seen these hang when i installed my karata...and give you a sense that the outer hub slid in the grooves of the basket and it wasnt...wiggled it and the hub slid in another 1\8 of an inch then adjusted out normally

 

[bigdogtech01]

It sound to me like the Ramp on the Actuator is not lined up correctly. When you loosen up the clutch the ramp sometimes moves forward as you disassemble the clutch. Therefore when you pull the lever you have no clutch, it is very hard to pull. You need to loosen up the cable and push the ramp back toward the rear, next adjust the clutch and then adjust to cable.

Good Luck

Carlos

Sounds like this is what went wrong with his clutch. That ball and ramp can fall out of place sometimes very easy if the cable is moved around via the clutch lever. For anyone doing this work. Make sure that when you go to adjust your pushrod that your cable is all the way loosened up and that when your looking down at the pushrod... Make sure that the ramp assy is sticking out around an 1/8". If i had a picture to put up it would be much eisier to explain. Basically, the inner part of the ramp ( the part that has the inner threads for the pushrods outer threads) has to stick out a little less than an 1/8" beyond the outer part of the ramp assy. There should be a lip. If it's flush then the adjustment will not work. That poping noise was the ramp going back into place. I'm sure he has all kinds of freeplay now. To get it back into place you might have to work at it a bit and sometimes can be a pain with the exhaust in the way. if the exhaust is off i will take the end of the rod and thread it in backwords so that you can use the rod to turn the ramp back into place. It's always worked for me.
Aslo a good way to adjust the clutch is...with the cable all the way loose, turn your pushrod all the way in till it bottoms out. Now go up to your cable and tighten it up to take all the play out of your lever. Now go back to your pushrod and turn it back a 1/4 turn. This will leave you with 1/8" of free play. It works great every time and comes out the same every time. Keeps everything tight and in it's place.

 

[RRRUFF]

Sounds like this is what went wrong with his clutch. That ball and ramp can fall out of place sometimes very easy if the cable is moved around via the clutch lever. For anyone doing this work. Make sure that when you go to adjust your pushrod that your cable is all the way loosened up and that when your looking down at the pushrod... Make sure that the ramp assy is sticking out around an 1/8". If i had a picture to put up it would be much eisier to explain. Basically, the inner part of the ramp ( the part that has the inner threads for the pushrods outer threads) has to stick out a little less than an 1/8" beyond the outer part of the ramp assy. There should be a lip. If it's flush then the adjustment will not work. That poping noise was the ramp going back into place. I'm sure he has all kinds of freeplay now. To get it back into place you might have to work at it a bit and sometimes can be a pain with the exhaust in the way. if the exhaust is off i will take the end of the rod and thread it in backwords so that you can use the rod to turn the ramp back into place. It's always worked for me.
Aslo a good way to adjust the clutch is...with the cable all the way loose, turn your pushrod all the way in till it bottoms out. Now go up to your cable and tighten it up to take all the play out of your lever. Now go back to your pushrod and turn it back a 1/4 turn. This will leave you with 1/8" of free play. It works great every time and comes out the same every time. Keeps everything tight and in it's place.

:2thumbs:

 

[DemonK9]

HAd the same shit happen…. Take off primary cover, tighten clutch basket bolt, thank god i took it apart me for i had too much primary case shaving in it, then the cluch basket cracked in half 200 miles later…..

 

[BadBrad]

This sounds just like what I did just a few weeks ago. I mean exactly! I thought I put everything back in the same order I took it off and went by memory even though I have a manual. You're probably not as big a fuck up as I am, but I had put the clutch diaphram spring on before the pressure plate. Locked the clutch up tight. No movement at all and when I finally figured out what I had done and reversed it, works like a charm. Generally I don't admit to screwing up so bad, but yours sounds identical to what I had done. My memory sucks, no doubt. Do you have a clutch assembly diagram to look at?

 

[pauldeepsea]

Wanna trade for an 04 Pitbull?