No idea how that happened other then you did that on installation. The two special plates are the second you put in with a wavy washer around it the last one you put in because it fits over the pressure plate.first off i want to say this thread is great. i will be installing a GYTR clutch in my buggy (raptor 660R engine) and the step-by-step is perfect for this first timer.
now....the questions. everything came apart slick as snot because my engine is in a buggy frame so i didn't have to worry about any obstructions but when i removed the screws, springs and cover this is what i was looking at (first pic). my clutch worked but was slipping because a dumbass (me) put the wrong oil in the case when i installed the engine.
looking at the first friction disc, it's in the wrong position!! it didn't damage anything as far as i can tell but how the hell did it get like that? secondly, look at the "notches on the first and second to last friction disc. only those two discs have that notch. if i am reading the post correctly those two discs with the notch are the two discs with the part number ending in 001 and go in the first position and second to last (going from outside in looking at the clutch)
** i should mention that when i bought the running quad the guy said he put an "aftermarket" clutch kit in it about a year prior **
You remove the lever from the clutch shaftAlright so I don't want to beat a dead horse but I'm still confused. I don't know if it cus I'm slow or just don't get it, but 2 questions what exactly needs to be done with the lever that goes into the case that the cable hooks to. Some say it need to come out, some say it doesn't, 1/2 in here, turn it clockwise, what needs to be done? That's part is fairly confusing. And #2 when adjusting the clutch after all said and done this free play you guys speak of, is it when the lever is all the way out and you have an 1/8 in of room where you pull the clutch lever in and nothing happens for 1/8 in then it has tension? Sorry if this is confusing but I am confused and I really don't want to burn up my new clutch or have any issues when I attempt this. First time working with quads... If you can't tell!
If you have the lever at the case set up properly as I've told you. You can adjust the freeplay in the cable at both ends of the cable. It doesn't matter which end you use or if you use both ends to adjust the freeplay. As long as the cable is loose. When you squeeze the clutch handle you should be able to see an 1/16-1/8 inch of freeplay in the cable. This allows the clutch disconnect mechanism to relax in the clutch housing and the clutch to grab. If you don't have freeplay in the clutch cable the clutch can slip.When you say Freeplay though, do you mean how much you can move the lever on the bars before it moves the clutch lever on the case? Because I've got the cable on the handle bars screwed all the way inn, and there still is not much free play at the clutch lever. What is the free play t there for?