Ball ramp is 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.

 

[Marky-Marc]

By oil leak, I hope you mean PRIMARY fluid leak?

Well, that has happened to me a few times in the past, long ago.....your clutch cable needs to be COMPLETELY collapsed, make sure the Clutch cable ball in the cover, and make sure it is CORRECTLY SET! I'm hoping you cleaned and greased your ball and ramp again and since you're where you're at, LUBED your clutch cable......Do you have a pic of how you say it is 'set correctly'?

ALSO, once it's completely collapsed, make sure the cable did not expand/get stuck/bind up somewhere along the way or in the hand controls.....what you are describing is if the cable is too short (obviously not, you're using the same one) or it's bound up somewhere and JUMPS! OR, push rod is NOT set correctly.....

Once cleaned, greased, cable lubed and correctly installed, put it back together. Adjust PUSHROD per manual or the tips on this forum....

THEN adjust clutch cable....Back in the day, many many years ago, I remember pulling my hair out like you are....something is 'not correct'....

Cheers!

 

[mleach72]

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.

I've never had this happen and I've had the ball and ramp opened many times. Are you fully loosening the clutch cable before taking apart and putting back together. I don't know if this will help, but I always crank the pushrod in a few turns past feeling pressure before final adjustment. This puts pressure on the ball and ramp and forces it fully to the rear.

 

[Mikeinjersey]

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.

This link may help you.

Dropbox - Error - Simplify your life

www.dropbox.com

 

[Twistedspoke100]

By oil leak, I hope you mean PRIMARY fluid leak?

Well, that has happened to me a few times in the past, long ago.....your clutch cable needs to be COMPLETELY collapsed, make sure the Clutch cable ball in the cover, and make sure it is CORRECTLY SET! I'm hoping you cleaned and greased your ball and ramp again and since you're where you're at, LUBED your clutch cable......Do you have a pic of how you say it is 'set correctly'?

ALSO, once it's completely collapsed, make sure the cable did not expand/get stuck/bind up somewhere along the way or in the hand controls.....what you are describing is if the cable is too short (obviously not, you're using the same one) or it's bound up somewhere and JUMPS! OR, push rod is NOT set correctly.....

Once cleaned, greased, cable lubed and correctly installed, put it back together. Adjust PUSHROD per manual or the tips on this forum....

THEN adjust clutch cable....Back in the day, many many years ago, I remember pulling my hair out like you are....something is 'not correct'....

Cheers!

That’s exactly what it was! Needed to collapse the clutch cable ALL THE WAY! got it it back together and running. Thanks!