clutch

[aubryblaster97]

well i ordered a new clutch cable and it seems like its too long. i move the arm that holds the cable to it. it wont even engage. when i start it up in neutrel,and put it in 1st it start to roll and slowly dies if i dont press the gas. what could cause this?

 

[slickerthanyou]

I'd start with doing the internal adjustment, then use the perch adjustment to get proper free play adjustment.

 

[Awk08]

sounds like you need an internal adjustment................

it took me 4 or 5 times to get this right the first time, very frustrating, do all this with the cable disconnected at the hand lever so it doesnt effect the internal adjustment, remove clutch cover, loosen the small locknut and screw in the middle of the clutch basket, back it out a little, (the adjustment shaft in the middle of the clutch basket) then where the cable connects to the motor lever on the shifter side, theres a notch that lines up, look on the engine lever for the little point and a mark on the case, line these up, make sure it doesnt move while adjusting, a freind would be good here, then move to the other side, tighten the rod in with a small screwdriver till you feel it touch, then back it off 1/2 a turn,then tighten the locknut, <<<<definately use locktite here, mine almost came loose, and thats disaster, then reconnect the cable to the clutch lever, and adjust your slack, i also did this with the wheels off the ground, so i could spin them with the clutch lever pulled in, to see if the wheels spun free, or if there was engine lag as i released it, before i put it all back together

 

[aubryblaster97]

do i need to empty the crankcase oil? and do i need a new gasket or can i get away with out a new one?

 

[slickerthanyou]

do i need to empty the crankcase oil? and do i need a new gasket or can i get away with out a new one?

Some times you can reuse the old one as long as it isn't torn! Yes you need to drain the tranny fluid!

 

[aubryblaster97]

okay, imma go drain it and get my friend to help me. but imma be asking questions along the way so check back guys!

 

[slickerthanyou]

okay, imma go drain it and get my friend to help me. but imma be asking questions along the way so check back guys!

We got ya! !

 

[aubryblaster97]

okay i got the clytch cover off and i dont know where to start heres a pic

 

[slickerthanyou]

Heres a few pages from the manual-

 

[aubryblaster97]

guide me on this!!!

 

[slickerthanyou]

Start with Page 3-11 number 13 but first remove the clutch cable from the clutch arm on the motor.

 

[aubryblaster97]

awk was talking about a screw?

 

[slickerthanyou]

Yip look at the pages i posted it gives step by step instructions with pics. But first remove the cable from the clutch arm!

 

[aubryblaster97]

okay, i got the cable off the arm. what next?

 

[slickerthanyou]

Start with Page 3-11 number 13 but first remove the clutch cable from the clutch arm on the motor.

do this now^^^^^

 

[aubryblaster97]

let me go get my clymer

 

[aubryblaster97]

okay i got my clymer, im on page 91 and what i basically need to do is hold the the clutch arm all the way forward and tighten the nut till it goes back?

 

[slickerthanyou]

ok, but all your doing is loosening that center nut on the clutch plate then, put light pressure on the clutch arm pushing towards the cylinder (front of the quad) and look for the little raised arrow on the case , Now if it is lined up with the point on the clutch arm no adjustment necessary, if it's not while still slightly pushing on the arm turn the phillips part of the rod until it lines up with the raised arrow on the case, if i remeber correctly if you ar past the arrow more towards the front on the quad then turn that philips counter clockwise, if your behind closer to the rear of the quad turn it clockwise just until the point on the arm and the raised arrow are aligned. Now tighten the nut to 5.1 ftlbs not super tight but good and snug, I use blue locktight on this!

 

[slickerthanyou]

okay i got my clymer, im on page 91 and what i basically need to do is hold the the clutch arm all the way forward

Yes but your not putting monster pressure on it just until it stops moving!

 

[Awk08]

no, hold the center rod with a screw driver and loosen the 10mm nut (center of the clutch basket, then align the clutch actuator pointer with the notch on the case,
turn the center rod in till you feel it touch, back it off a 1/2 turn, re-tighten 10mm nut
replace cable, adjust slack, test to see if it's pushing the pressure plate out

all of that was explained in my first post, and in the manual slick posted.
step back, take a deep breath, then read and do, one sentence at a time, in either of those above posts