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Discussion Starter #1
I just replaced my clutch assy with a new one from the motorco. Reason was the clutch hub bearing was on its way out, and the flywheel had some bad teeth. The assy is a complete assembled unit, so I just bolted it in. Now after adjusting the clutch hub, I cant get the freeplay from the lever without running out of threads on the cable. Seems there is too much play in the clutch movement. Is there a ball on the end of clutch push rod? I had the rod out, just wondering if something changed on the clutch lever housing end.
 

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Discussion Starter #4
I adjusted by the book. Put freeplay in the cable, adjust the clutch hub tilll its lightly seated, then back off 1/2 to 1 turn. Then try to take the slack out of the cable. I run out of threads on the cable adjustment before the freeplay of the cable is removed. Clutch assy is complete and assembled from the motorco. Visually checking the stack height, it looks correct and the same as the clutch assy that was removed. Trap door has not be removed.
 

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Squeeze the clutch lever a few times as it sits, this should ensure that the release balls are seated where they should be.
Now, loosen all the slack again, this should put the clutch lever right against the grip or very close. Loosen the clutch adjuster locknut, with one hand on the clutch lever, screw the adjuster screw in till you just feel the lever start to lift. Back the adjuster out 1/2 turn and lock the locknut.
Re-adjust the cable till you have 1/16" slack available at the lever.

If this doesn't work out, or if anything feels or looks funky you'll need to pull the trap door off and check the release cam assembly, it's possible that it dropped a ball out.
 

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looking at my manual I can't see how the balls can come out on the ball and ramp but it could be possible that the cable came loose on the ramp coupling inside the trap door.
 

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Discussion Starter #7
I removed the door, and sure enough the balls had fallen to the bottom of the ramp. I replaced em, and readjusted everything. Feels like a new bike again!
 

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since you had it apart maybe you can tell me how the balls can come out with the retaining ring in place? could it have something to do with pulling out the rod? just trying to increase my knowlodge on how it works.can't tell from the manual.
 

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Discussion Starter #9
I think since having removed the rod, there wasnt any pressure against the ramp assy, so it allowed it to cock sideways, dropping the balls to the bottom. I can understand thinking it shouldnt be possible, as I was hesitant to remove the trap door thinking the same myself, but rest assure it is possible.
 
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