Full pressure to no pressure? Clutch issues

[Empire087]

Ok, so I had to ride my blaster to work a few months back I got there and noticed I was dripping some fluid. It had looked like it stopped so I rode it back 11:00 pm at night. Cruised back at around 45 mph, let it idle down and put it away in my garage. Needed it the next day and come to find out there was no clutch pressure. Low on fluid but not zip, filled it up and still had no pressure. Fast forward to 3 weeks ago. Pull the motor and find there is grooving in the baskets and find a post in the inner boss snapped with shaving in the trans. I didn't find any push bearing like there was supposed to be. Is it possible it moved inside its area? Also the clutch arm was moving. Just trying to figure out where to go from here. I'm ordering a new inner boss, and replacing the mangled bolt. I can work on a sled from the ground up, but 4 wheeler transmissions are just a little bit new to me. Once I learn them I'm golden, just need to get there.

Thanks,
Dakota

 

[scotj77]

Re: Full pressure to no pressure? Clutch adjustment

well there are 3 pieces inside the main transmistion shaft that seperate the pressure plate from the clutch discs when you pull the clutch lever. fluid only lubricates everything. probably not the issue. you have a long rod that contacts the clutch actuator then a 3/16 ball bearing then the rod that is threaded on one end that is attached to the pressure plate. this kinda sounds to me the outside nut on the clutch pressure plate, loosened, fell off and hit one of the spring bolts and broke the piece off. this would explain all of your problems

 

[Empire087]

Ill also note that the nut inside the clutch basket wasn't tightened or threaded to anything. The clutch plates where also all stuck to each other.

 

[scotj77]

ummmmm can i see the front of the pressure plate? you mean the main nut that holds the clutch basket on was loose? the washer that you bend around the nut wasn't there?

 

[scotj77]

wait i see the washer that holds the main clutch retainer nut inplace sitting on the back of the pressure plate. is that where it was when you pulled it appart?

 

[Empire087]

Here's the pic, the larger nut and washer where what I mean. The thick washer is like stuck go the push rod on the pressure plate.

 

[scotj77]

yeah it should be. that is one piece. well i would say it is all due to your main nut backiing off in there. just make sure you bend that washer up around the nut when you put it back together

 

[sporty982000]

Looks like you gonna need to file down those groves on the clutch basket and pick up a used clutch boss.


Sporty

 

[scotj77]

after something like that happening you need to really inspect all that suff for damage. take some pix if you think you find something. there are always scuffs on the outside of the basket. they come that way

 

[sporty982000]

Looks some there is a washer missing ? a thicker one ??? (spacer) cant see it in the pic. might still be on the shaft.


Sporty

 

[mud runner]

post a close up picture of the acuator

 

[Empire087]

Tomorrow ill get a pic of everything that came out. I'd also just like to say thank you guys for the help, makes things a lot easier.

 

[slickerthanyou]

Looks some there is a washer missing ? a thicker one ??? (spacer) cant see it in the pic. might still be on the shaft.


Sporty

Good eye!

Not really called a washer, But a thrust plate, It's #5 on the diagram.

Also make sure before you put the basket back on there are two washers on the shaft #13 and #14 on the diagram, the thinner one (conical-spring) goes on first then the thicker (plate washer) one!

 

[Empire087]

Heres the pictures, if more is needed let me know.

 

[sporty982000]

Look at the diagram, it does appear, you are missing (#5),late, thrust 1.


Sporty

 

[Awk08]

without reading thru the above posts..........
where is the inner ball bearing that goes between the 2 actuator rods, i don't see it in the pics ???

 

[mud runner]

well when mine went out there was a chunck missing in the acuator i put a new one in there and it works good now

 

[sporty982000]

without reading thru the above posts..........
where is the inner ball bearing that goes between the 2 actuator rods, i don't see it in the pics ???

Good catch,


I dont see that either.

Sporty

 

[scotj77]

missing those two things= no clutch

 

[Empire087]

Yeah, the ball bearing is gone. No idea where it is. I'll look for that #5, starting to worry about the bottom end the previous owner did. Strange that I'm missing that one part. Would it have worked without them?