banshe98 Posted February 29, 2004 Report Share Posted February 29, 2004 Banshee is running great. I was riding today and everything was fine and went to downshift and pulled the clutch in, but it is like something is froze up or something. The banshee still drives great and it will still shift up and down, but you can't use the clutch. Should I drain all the fluids and check everything out. I've never did any clutch work and am not really sure what I need to do. any help would be appreciated Quote Link to comment Share on other sites More sharing options...
vmaxup Posted March 1, 2004 Report Share Posted March 1, 2004 Take your clutch cover off and have a look. Common problem If everything looks ok. try to pull the clutch in. If it barely or dosent move your rod and ball are probabbly welded together. You have to take all the springs of the clutch. Then the outer cover of the clutch should come off. If you cant get it off easiely the rod is welded too the ball and the adjuster . The only way to free this is to tap on the adjuster in the center. once you get it off you will see your problem. But dont worry the fun has just begun. You have too disasemble the motor to get the rod and ball out. it nwill probabbly be mushrumed down by the clutch cam that your cable is connected too. SO you have too split the cases and replace the cam the rod the ball and the adjuster. I had this happen twice too the same shee. Then from some great info from the guys on here. It was too run 2 quarts off oil instead off recomended level. It keeps all these part submerged in oil. I have had no problems since. I also have no oil leeking anyware from the extra oil. if you need more details let me know. It is a pretty simple system if you look at a picture. Just alot of time too do the fixen. Let me know if you need some help with the walk throught. Eric Quote Link to comment Share on other sites More sharing options...
sandman121383 Posted March 1, 2004 Report Share Posted March 1, 2004 he's right dude. if u can only pull ur clutch cable so far then it just stops well then u got problems. if u can't get the rod an ball out with a magnet ur gonna have to take ur motor out. it happened to me b4. i took out my engine . flipped it upside down on my bench and took the bottom end off to get it out. wasn't the most fun i had in awhile but i learned alot and im not afraid of takin it apart anymore. i can't wait till top end rebulid time Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 1, 2004 Author Report Share Posted March 1, 2004 ya I haven't taken it apart yet, but It is like the clutch shaft is totally engaged (all the way in). there is a lot of slack in the cable, but the cable is in good shape. I'll know more when I get it apart, but I'm hoping that it is just a clutch basket or clutch problem. I'll let ya know more when I get it apart. thanks Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 3, 2004 Author Report Share Posted March 3, 2004 ok, I took the clutch springs and the clutck plates off. Tell me if this is right. Is the rod 2 pieces. There is the threaded small part, then the ball, then the other long part of the rod. I pulled this out as all one piece. the ball is welded in between these 2 pieces. I'm just wondering what I need to do next. also, what should the other end of the rod look like. I'm just wondering where my problem is at because I still can't move the clutch lever that is on top of the motor. Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 3, 2004 Author Report Share Posted March 3, 2004 The clutch lever on top of the motor is now free and rotates smoothly. I'm just wondering what I need to do about the rod and ball now. am I correct that the ball should be free of both sections of the rod. any help is greatly appreciated. Quote Link to comment Share on other sites More sharing options...
chipdog Posted March 4, 2004 Report Share Posted March 4, 2004 Take your clutch cover off and have a look.Common problem If everything looks ok. try to pull the clutch in. If it barely or dosent move your rod and ball are probabbly welded together. You have to take all the springs of the clutch. Then the outer cover of the clutch should come off. If you cant get it off easiely the rod is welded too the ball and the adjuster . The only way to free this is to tap on the adjuster in the center. once you get it off you will see your problem. But dont worry the fun has just begun. You have too disasemble the motor to get the rod and ball out. it nwill probabbly be mushrumed down by the clutch cam that your cable is connected too. SO you have too split the cases and replace the cam the rod the ball and the adjuster. I had this happen twice too the same shee. Then from some great info from the guys on here. It was too run 2 quarts off oil instead off recomended level. It keeps all these part submerged in oil. I have had no problems since. I also have no oil leeking anyware from the extra oil. if you need more details let me know. It is a pretty simple system if you look at a picture. Just alot of time too do the fixen. Let me know if you need some help with the walk throught. Eric WHAT KIND OF OIL DO YOU USE IF YOU PUT TWO QUARTS I WOULD THINK YOU WOULD PROBLY OVER RUN IT. Quote Link to comment Share on other sites More sharing options...
MotulMonsta Posted March 4, 2004 Report Share Posted March 4, 2004 The rod should be only one piece, with the ball sitting at the end before the clutch adjuster. The clutch aduster has a long screw that contcts the ball, while the housing that the screw is in rests against the outer clutch pressure plate. The rod itself inturns contacts the cam on the clutch activation lever where the cable connects to. If it's broke in two, thats your problem right there. The stock bashee case will hold close to 3 quarts of oil. I recomend running the oil halfway on the dipstick lines. I also recomend using basic engine 10w-40 wt oil with no additives as they can adhere to the clutch plates reducing friction. Synthetic oils are also advised against as they are formulated with friction reducing additives. Sounds funny, but you don't kneed all that friction reducing mumbo jumbo, it will mess up your clutch plates. 80wt gear oil works good too. Do not run transmission fluid. Your bearings will seize. Cheap havoline 95 cent a quart oil works good. Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 4, 2004 Author Report Share Posted March 4, 2004 ya, the ball is welded to the end of the rod and the clutch adjuster. does this mean that i need to buy a new rod, ball and clutch adjuster? Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 6, 2004 Author Report Share Posted March 6, 2004 does the clutch cover gasket have to be replaced because mine still looks like it is in really good shape. Just wondering if I should replace it. Quote Link to comment Share on other sites More sharing options...
geaux 4 it Posted March 7, 2004 Report Share Posted March 7, 2004 No .You can reuse it. Quote Link to comment Share on other sites More sharing options...
bakestrumz92 Posted March 7, 2004 Report Share Posted March 7, 2004 how can i keep my clutch ball, rod, and adjuster from becoming welded together? seems like a real pain in the ass to fix and something id like to avoid. thanks for the help Quote Link to comment Share on other sites More sharing options...
MotulMonsta Posted March 7, 2004 Report Share Posted March 7, 2004 Run good oil and keep it between the lines of the dipstick. Don't use ATF, Dextron/Mercon, Don't use any stabilizers..just good ol oil. 10w/40wt petrolium based. the 95 cent a quart oil. Quote Link to comment Share on other sites More sharing options...
banshe98 Posted March 24, 2004 Author Report Share Posted March 24, 2004 I got everything put back together and it was running great, but after a little while the exact same thing happened. I took everything apart again and the rod and ball are welded together. I put about 1.8 quarts in. I'm just wondering if I should be putting more fluid in so I can keep this from happening again. Also, is the yamalube 4 10w30 ok to use. All help is appreciated because I really don't wanna take everything apart a third time. thanks Quote Link to comment Share on other sites More sharing options...
boonman Posted March 25, 2004 Report Share Posted March 25, 2004 When you are moving, don't pull the clutch in for long periods of time..... That is what welds them up. Sitting still with the clutch in is alright, but when you are let's say rolling down a hill and you pull the clutch in, and hold it in, you just screwed up and welded them..... that's a no-no Quote Link to comment Share on other sites More sharing options...
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