It's Alive.....kinda.

[90Zilla]

Well I got eveything back together and on about the fourth kick it fired up and idled great. Now to the good stuff, when I was redoing the water pump I noticed that there is a ridge in the case under where the mechanical seal sits, kinda like where it stops when you put it in. The ridge is missing about a quarter inch section or so. Looks like someone before me got hammer happy. Is this fixable or will I need a new clutch cover? I am guessing this is letting water past the mech seal and out of the weep hole. I also need help with adjusting the clutch. My buddy just bolted the case on on said it would be fine, but I can't seem to get the clutch to release no matter how much I adjust it. Is there a certain way maybe the rod has to line up? Maybe someone could walk me through getting the clutch hooked back up right. Thanks for all the help, and at least the topend job was a sucess. I would really appreciate any knowledge anyone has in the areas I am having trouble with. Thanks guys.

[sblt500r]

that ridge in the clutch cover is there to seperate the oil seal and the mechanical seal. it doesn't stop the mechanical seal. the lip on the mechanical seal stops it from going in to far. if your just missing 1/4 inch piece of it that should still work fine. did you change the rubber washers on the impellar bolt? alot of people miss that.

as for the clutch, turn the cable all the way in on the clutch cover, and turn the adjuster all the way in on the clutch perch. then take of the aluminum arm on the clutch cover that the cable goes in. turn the shaft that sticks out of the clutch cover all the way to the front of the quad. then put the arm in the cable, and put it back as far as the cable will allow, and then slide it over the splines, and tighten it up. now adjust the clutch cable, on the clucth cover, till the clutch lever feels good. then try it out. if you can understand that, you will be all set

[90Zilla]

I still can't seem to get the clutch to engage right. When I get the clutch to engage, it only does about half ass and then the clutch lever doesn't even make a difference because the adjustment on the cover is out so far. I don't know what I am doing wrong, but I did it just like you about five times. On a lighter note, after the topend rebuild and the jetting help, it fires up on the second or third kick.

[90Zilla]

Any other suggestions on what It may be? It worked fine before. I just don't understand.

[90Zilla]

Brainfart.... When my buddy and I were taking the bike apart for the rebuild, I told him to go ahead and drain the oil and unbolt the clutch cover. I remember coming around the bike and seeing him prying the clutch perch on the cover forward trying to get the cable off. Could he have pushed it too far forward and damaged something? I don't know why I just now thought of that, but I remember now. What kind of damage could that cause? I know it wouldn't stretch the cable like that since all the tension was off of it. I am clueless.