Fighting My Clutch

[flcmcya]

Replaced the starter on my 05 Bulldog,

Trying to shortcut I removed the clutch adjustment cover thinking I could slide it out with the rod in place and slide it right back in......

....after removing my battery box to get enough clearance I finally made the swap.... then slid rod in and bolted her up.... No clutch!

Took the adjustment rod out correctly anfd reinstalled ...no clutch....... Checked the ramp out a couple times.... still bound up. I didn't pull the ramp all the way back prior to reinstalling the lid so I will try that tonight.

Any ideas what I jacked up?

 

[Th3InfamousI]

You should have been fine sliding it and back in but you'll have to start from scratch on the clutch adjustment. You actually didn't need to touch the ball and ramp.

Do you have any pressure non the clutch lever?

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[flcmcya]

Clutch lever feels like it is locked up ...missing that normal smooth pull.

and I had to spin out the adjustmen almost all the way to tighten it up.

 

[BWG56]

Did ya bend the rod? That's a long rod to pull straight out with the cable connected to it.

 

[flcmcya]

Don't believe so Ker,

Later when I unscrewed it, she pulled out smoothly without any obvious issues..... one of the things I was looking for.

 

[BWG56]

Did ya check the cable adjustment under the boot on the down tube?
I wonder if the ferrule came off the end of the cable by the ball n ramp

 

[Marky-Marc]

IF YOU DID NOT TAKE BALL AND RAMP APART, you just need to do a normal clutch adjustment per manual......

HOWEVER, since your clutch is HARD to PULL (that's what she said), AND since you pulled ROD out without disconnecting cable FROM BALL AND RAMP with drive belt guard, I'm assuming you pulled it out with belt guard still on, and you had to have used a little 'force' as mentioned above, your ball and ramp probably jumped a 'ball' (that's what she said), while you were pulling it out with drive belt guard still attached to Rod.

Now you will need to disassemble ball and ramp and re-seat ball bearings correctly....IF YOU'VE already reassembled ball and ramp, and still doing the same thing, you re-assembled incorrectly.....

Picture attached of inside of drive belt guard ball and ramp chamber disassembled....

 

[Marky-Marc]

Backwards ball and ramp assembly pics since this cover is off.....how ball and ramp should initially installed BEFORE ADJUSTING clutch cable....

REMEMBER, THIS IS BACKWARDS from what YOU ARE LOOKING AT FROM THE OUTSIDE.....

Initial ball and ramp seating from Inside. This would be your OUTER ramp if you have outer small round cover off with guard ON!


Inner Rod pic.....sitting on outer ramp.....



Back to my Heineken and garage door.....

 

[flcmcya]

Right on Marc

I took it apart , cleaned and lubed, then reassembled everything

Thats my move tonight as I didn't pull the cable all the way to the right when I reassembled it and made adjustments.

Thanks for the pics.

On another note I couldn't see how the cable comes out of the outer ramp.... as yours is missing...... and there is no slot in the arm.

 

[Marky-Marc]

Ferrule ball....lol....here's a pic.....cable goes through housing, through shaft, hooks to ferrule ball that seats it in Rod ball and ramp side/housing....that's what makes it move back and forth.....

You should have THREE balls (that's what she said) for the ball and ramp, and ONE ferulle ball to hold cable in slot on shaft ball and ramp side....

 

[Marky-Marc]

#51 is the ball that holds the cable....

 

[flcmcya]

Crap!

I'll definitely look for the dreaded fourth ball!

Thanks for the pic,

Can't see that binding anything up but would sure suck if it isn't there.

 

[Th3InfamousI]

#51 is the ball that holds the cable....View attachment 35198

You wanna see my ball that connects to my LArge cable? Part #1 or Part #2...haha

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[Th3InfamousI]

Crap!

I'll definitely look for the dreaded fourth ball!

Thanks for the pic,

Can't see that binding anything up but would sure suck if it isn't there.

Let me know if you need pictures of something I'm about to talk it all apart on Thursday.

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[Marky-Marc]

You wanna see my ball that connects to my LArge cable? Part #1 or Part #2...haha

Sent from my 831C using Tapatalk

 

[Marky-Marc]

Crap!

I'll definitely look for the dreaded fourth ball!

Thanks for the pic,

Can't see that binding anything up but would sure suck if it isn't there.

If your ball and ramp jumped, it will bind up....

 

[flcmcya]

Somebody mentioned that sleeve in another thread.....

... I didn't find one laying in the ramp housing! So it must be on there.

The ramp is the only thing I can think of that would be binding up though.

 

[BWG56]

Did ya check the cable adjustment under the boot on the down tube?
I wonder if the ferrule came off the end of the cable by the ball n ramp

Somebody mentioned that sleeve in another thread.....

... I didn't find one laying in the ramp housing! So it must be on there.

The ramp is the only thing I can think of that would be binding up though.

It was in this thread

 

[Mr. Wright]

Backwards ball and ramp assembly pics since this cover is off.....how ball and ramp should initially installed BEFORE ADJUSTING clutch cable....

REMEMBER, THIS IS BACKWARDS from what YOU ARE LOOKING AT FROM THE OUTSIDE.....

Initial ball and ramp seating from Inside. This would be your OUTER ramp if you have outer small round cover off with guard ON!
View attachment 35189

Inner Rod pic.....sitting on outer ramp.....

View attachment 35190

Back to my Heineken and garage door.....

Make sure you use the three ball bearings, and not the clutch cable clip ball, like Marky is, in the picture.

 

[Marky-Marc]

Make sure you use the three ball bearings, and not the clutch cable clip ball, like Marky is, in the picture.

Dick! I realized after that I threw the sleeve in instead of MY other ball after I posted! Bwahahahah.....