Over the winter I had the primary all apart to change to a 30 tooth pulley. So I finished up about a month ago and everything seemed fine. Well the weather here has been crap until today. I went to give it a test spin and started her up and the clutch wouldn't engage. So, I grab the manual and go to adjust it. I made a couple of tries by the manual and still no luck. To make matters worse, now, after a third attempt to adjust, I go to take out the free play and turn the adjuster barrel right off the threaded part. I threaded back on and tried adjusting the pushrod again and now it feels like something came apart because when I squeeze the clutch lever something feels like it snaps. I don't know how to proceed, am I going to have to pull it all apart again?

 

Sounds like you need to go around to the cable side and see what happened in there.

 

Yep, if someone squeezed the clutch lever when you had it all apart, you may have flipped the 3 Ball ramp inside the clutch actuator on the right hand side. When you get it apart, pull the cable taught against the lever ( take up the slack, ) and install the cover with ramp back on.

 

thanks guys, I'll give that a try.

 

This happens every time I put a 4 speed Sporty primary back together and I cure it by over tightening the adjust to make sure its all bedded in, then I slack off the adjuster and find that the "tight point" is further than before. Re-adjust, set the cable adjuster and its all good.

 

Okay, I pulled the righ side cover and checked out the ***** and ramp. Everything seems okay. Upon reassembling it still does the same thing. Feels as though the ramp doesn't push the push rod but slips. I'm lost now. No clue what to do next. If I'm understanding this correctly the ramp pushes the rod when the clutch lever is pulled. Something I'm missing?

 

Wen you reassembled the right cover, the slack was out of the cable and the ramp's arm was pointing down at say, 7 O'Clock?

 

No, more like 5 oclock, I'll recheck.

 

Clutch problem ended up being the snap ring in front of the adjuster cover not being fully seated. Must have been just enough to cause it not to engage. Then, of course, I found that I had a bad seal on the main shaft so I had to take it all apart again to replace the seal. Now I have starter issues. May have to take the outer cover off to lube up the jack shaft. When stuff goes wrong it seems to be in bunches!