Hoping someone with some clutch experience could help me troubleshoot this one. I have been running RWR 60% springs on stock clutch for about six months, and have not had any problems with my clutch until my last trail ride yesterday. As I pulled the clutch lever in while shifting between gears the clutch lever did not want to return. It was as if the clutch became stuck while open. I fiddled with the lever a few times and it violently released stalling the bike. It did this twice in a very short time then never acted up again. The rest of the riding day however shifting between gears seemed very notchy and I had a hard time finding neutral when coming to a stop. The clutch now also seems to have a very distinct point after about 3/4 pull-in that it feels like the spring tension almost doubles for about the last 1/4 pull. Looking for any ideas before I pull the clutch cover to see what it going on.

 

Possibly the actuator has some chipped teeth.??

 

actuator there is a newer version

 

updated one? where who?

 

WHen did this new actuator you speak of come out and what is different about it? Do you have a part#?

Thanks.

 

Just found the part# in another thread http://forums.atvconnection.com/mess...word1=actuator

It looks like I already have the updated actuator since my DS is an 04.

 

Actuator. My kids did the same thing. a little pricey to fix I thought.

 

Removed the clutch cover last night and found the entire middle tooth missing on the actuator. The rest of the teeth still looked like new. Luckily the missing tooth wedged itself between two other teeth on the actuator and I was able to recover it.

My question is on removing the actuator. I removed the C-clip but am I also going to have to remove all of the clutch springs and basket to get it out?