Ok so I got an 02 blaster for free and been working on it she ran completely fine except for the clutch was almost all the way out before it would engage so I bought new plates an springs an I noticed once I took it all apart the adjustment rod was stripped out bought new rod nut an bearing an read ur alls form with everything everyone has said I applied everything an the clutch still isn't right it's when I pull the clutch in it's like the cable is too long is it possible for the cable to stretch 2 - 3 inches an when I try to adjust the rod on the pressure plate there's not enough threads left for the locking bolt to thread on something isn't right please help
Clutch not adjusting right
- Thread starter Fitchy
- Start date
To clairify a bit:
1. How much free play does the lever have on it?
2. Is the actuator arm lined up with the arrow on the top case?
3. What type of tranny oil you use?
4. On the handle bars, you sure you can't adjust it further? Might be some dirt lodged in the threads( doubt it, but worth a check)
From reading through your post a couple times, I'd guess the push rod welded itself to the ball. That's due from a lack of grease or for example going down a hill or coasting with the clutch disengaged and a lack of tranny oil.
1. How much free play does the lever have on it?
2. Is the actuator arm lined up with the arrow on the top case?
3. What type of tranny oil you use?
4. On the handle bars, you sure you can't adjust it further? Might be some dirt lodged in the threads( doubt it, but worth a check)
From reading through your post a couple times, I'd guess the push rod welded itself to the ball. That's due from a lack of grease or for example going down a hill or coasting with the clutch disengaged and a lack of tranny oil.
The lever has slack even with the adjustment on the bar is all the way out it's still too much slack an I'm running ATF fluid but right now there is none in there due to installing new clutch I should be able to pull the lever in an it work with no fluid a couple times to insure everything is working as it should also it seems like the rod is to short an I aligned everything up as far as I kno dots to dots on pressure plate to inner basket but I've seen this a couple of ways with the snap ring I've seen it placed between 1st an 2nd friction disk an 2nd An 3rd right now I have mine between 1st an 2nd disk
On your steel plates, are they smooth all the way around the outside diameter? Or is there a notch that sticks out on them?
And you put them in order of fiber/steel/fiber/steel? Or vice-versa? Not sure what order the clymers has them.
Pressure plate is installed correctly? A tight fit in the basket?
If all checks out I'd see if you can get the push rod and clutch ball out and inspect it. Could be welded together.
Pressure plate is installed correctly? A tight fit in the basket?
If all checks out I'd see if you can get the push rod and clutch ball out and inspect it. Could be welded together.
Fiber steel is the order an I put the notches all facing the same direction pointing almost at the 12 o clock an put brand new push rod an ball an adjustment rod I did notice the big o ring between the first an second plate is very warped could this be why the adjustment rod is maxed bc the ring is taking up space when it shouldn't be bc it's warped
That's a problem. Rotate every steel plate 60 degrees clockwise upon installation. The notch on top of the steel plate should be installed every 60*
you have 7 fiber and 6 steel plates. Install fibers first like you did. When the steels are installed correctly, the notch on top of the steel plates will make a complete circle. Kind of hard to explain, I'll see if I can grab a picture from my clymers.
Take that wavy disc (warped) out and throw it away.
It is supposed to sit inside the fiber that has the larger inner diameter, in the second fiber position, that allows it to sit flush inside.
It sounds as if you overlooked that different fiber and just threw it in there anywhere ?
It's 100% uneeded, and can be discarded.
Its purpose was to cushion the clutch for new riders.
Some new clutches come with a full size fiber to replace the one the wavy disc sits in,
Some come with the correct fiber for it, either way it can be left out.
And thank you for your service !
It is supposed to sit inside the fiber that has the larger inner diameter, in the second fiber position, that allows it to sit flush inside.
It sounds as if you overlooked that different fiber and just threw it in there anywhere ?
It's 100% uneeded, and can be discarded.
Its purpose was to cushion the clutch for new riders.
Some new clutches come with a full size fiber to replace the one the wavy disc sits in,
Some come with the correct fiber for it, either way it can be left out.
And thank you for your service !
I wanna thank everyone for there inputs I believe it was the warped snap ring an I found the smaller disk or skinny one an placed her where she needs to go an took the snap ring out an also rotates the metal disk every 60 degree she adjusted fine an in working order y'all are amazing thank you again
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Ok so I took the blaster out to go ride an the clutch feels good has tension an everything clutches in to gear an goes no where I am completely dumb founded took the cover off on the spot an pulled the plates an put the snap ring back in an nothing still any ideas
Update Issue so far was inner basket was spinning with out the outer went through the plates put back to the best of my knowledge got the inner basket to stop spinning by itself put all back together now it goes into gear fine an takes off but only goes like 2mph it has like no power is it possible I adjusted it to tight with the adjustment rod the lever has no play what so ever an the lever is blocking from disengageing the clutch all the way ????
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