I am at wits end with this clutch. Any help?

[mrwhipper]

Hello all. Please let me give you the low down. I purchased this 97 Kat last year and the clutch as been strange since I bought it. I order to release enough to shift you have to CRANK down on the adjustments. This continued to get worse through the riding season last year. So, after reading some of the threads people were saying that the metal plates could be warped. This year I inspected the clutch and sure enough the metals were discolored, so I replaced metals, frictions and springs with all Barnett parts. No luck. I found some damage on the sprocket cover so I replaced the cover and the worm gear that connects to the clutch cable and pushes out the pressure plate. Still no luck. If you are thinking that I am not adjusting the clutch correctly, here are my steps.

1. winding in all cable adjustments.
2. Loosing nut for adjustment screw on worm gear.
3. Turning in set screw until I feel tension
4. Loosing screw 1\4 turn
5. tightening nut while holding screw
6. setting coarse adjustment until I have about 1 inch play on lever end
7. Setting fine adjustment until I have about 1\2 inch play on lever end

If there is around 1500 to 2000 RPM it will not go from neutral into gear with out grinding weather I have the clutch adjusted correctly or if I have too much adjustment in it. It does have a hard time finding neutral when it is in gear.

Any ideas?????? Or if there is a motorcycle tech in the North Eastern Lancaster PA area. I will pay to have it fixed. Thank you for any time that you can give me. I don't want to hurt the new clutch.

[steves]

Was the push rod ever damaged?

[mrwhipper]

Was the push rod ever damaged?

That is a great question. The best I can tell you is that I took it out and rolled it on the kitchen counter and it appeared to be true.

[joseph2027]

that doesn't realy work. it could be out micros of any amount and that could be the prob

[steves]

That is a great question. The best I can tell you is that I took it out and rolled it on the kitchen counter and it appeared to be true.

Ask Chris to measure one for you, and see if it's LONG enough.

[mrwhipper]

Ask Chris to measure one for you, and see if it's LONG enough.

Thank you for your time and I will ask, but it is more like there is not enough throw then adjustment. Like the worm gear is not pushing the shaft far enough or the cable is not moving far enough. Does that make sense?

I have to run out, I will be back in a bit.

[steves]

That's what I'm saying. Maybe the PO damaged it, chipped the end off the push rod... then just ground it down and slapped it back together.

[suzukiray]

I agree with Steve here. You need to measure the pushrod length. Ray.

[hardlydangerous]

first off why would you try to put it into gear at 1500-2000 rpm

idle speed is 1200

as for your settings not enough push rod free play... too much lever free play
try this

1. winding in all cable adjustments.
2. Loosing nut for adjustment screw on worm gear.
3. Turning in set screw until I feel tension
4. Loosing screw 1/3 to 1\2 turn
5. tightening nut while holding screw
6. setting coarse adjustment until I have about 1/2 inch play on lever end
7. Setting fine adjustment until I have about 3/8 inch play on lever end

[mrwhipper]

first off why would you try to put it into gear at 1500-2000 rpm

idle speed is 1200

as for your settings not enough push rod free play... too much lever free play
try this

1. winding in all cable adjustments.
2. Loosing nut for adjustment screw on worm gear.
3. Turning in set screw until I feel tension
4. Loosing screw 1/3 to 1\2 turn
5. tightening nut while holding screw
6. setting coarse adjustment until I have about 1/2 inch play on lever end
7. Setting fine adjustment until I have about 3/8 inch play on lever end

Thank you. I will give it a try. I was just trying to diagnose a problem. That is why I was trying different RPMs

[darrell3535]

can someone please tell me how to remove the clutch cable at the sprocket end? I found this thread, but it seems useless, and doesnt seem to explain things very well

http://katriders.com/vb/showthread.php?t=64698

I loosened the screw under the rubber grommet and the clutch cable will not come out...how does that assembly ebven work if you can see or know how the end of the cable is being grabbed?...frustrated to no end.

[Kreylyn]

can someone please tell me how to remove the clutch cable at the sprocket end? I found this thread, but it seems useless, and doesnt seem to explain things very well

http://katriders.com/vb/showthread.php?t=64698

I loosened the screw under the rubber grommet and the clutch cable will not come out...how does that assembly ebven work if you can see or know how the end of the cable is being grabbed?...frustrated to no end.

You need to pull the cover off that spot to access the lever inside your cable is attatched to in order to fully remove the cable. It's just a few bolts, and once it's off... it should be pretty clear what to do at that point.

Krey

[mrwhipper]

first off why would you try to put it into gear at 1500-2000 rpm

idle speed is 1200

as for your settings not enough push rod free play... too much lever free play
try this

1. winding in all cable adjustments.
2. Loosing nut for adjustment screw on worm gear.
3. Turning in set screw until I feel tension
4. Loosing screw 1/3 to 1\2 turn
5. tightening nut while holding screw
6. setting coarse adjustment until I have about 1/2 inch play on lever end
7. Setting fine adjustment until I have about 3/8 inch play on lever end

It did not make a difference. Thank you for the idea. If you have any others, please let me know. I am starting to think about a rag and the gas tank.

[darrell3535]

apologies...was a bit frustrated earlier. The error was on my part as I mistook the "How to adjust the clutch cable" for the "How to remove the clutch cable". I completed the job this evening. I can always count on quick responses from you guys..have a great evening.

[mrwhipper]

Ask Chris to measure one for you, and see if it's LONG enough.

Mine is the same size as Chris's. Any other ideas?