Ball and ramp keeps jumping

[Twistedspoke100]

I’m getting pretty frustrated anybody ever have this happen? I removed the pulley cover on my 05 Mastiff to replace the Starter o ring, to hopefully fix my oil leak. I loosened the cable and removed the push rod then I removed the cover. I reassembled in the reverse order and when I pulled the lever the ramp jumped over the balls loosing clutch pressure. Took it apart opened up the ball ramp reset it to where it should be put it back together and when I pulled the lever it did it again. What am I missing or doing wrong? Keep in mind the clutch was adjusted and worked perfect before I removed the pulley cover.

 

[Olde Man]

If I remember correctly when that happened to me the balls were out of position when I put it together. Heavy wheel bearing greese installed when you put it together might be the answer.

 

[hawaiian son]

I recently had that happen to me with my 2006 K9, I too took it apart and reassembled it(3x) it was also heavily greased. A friend suggested I hand the ball and ramp to a soft ball and ramp (from Baker transmission). Can’t understand it but after reassembled with new one it worked , no more jumping of the ramp.

 

[Th3InfamousI]

Only way I think it can ever jump the ramp is if you don't have it assembled right from the very start. There's a tab on the outer ball ramp that sits in the small recessed area on the cover so that plate will NEVER move! Then the balls with grease so it sticks in place and the inner ramp with the cable FULLY RELAXED and ramp faced towards the rear of the bike.