Hey guys! i know I am asking a question about my daughters Suzuki but you always have the
answers so here goes. So I am adjusting the clutch on my LTZ 400 tonight and the strangest thing happened. The quad was lurching when we start it even with the clutch fully in. So I decided to change the puller one tooth to help the clutch engage fully. When I disconnected the cable at the motor end the gear seemed to disengage inside the motor. Now it has no tension and the clutch won't return when you let go. I did not put much pressure on the cable clasp/gear when I disconnected the clutch cable so i am very perplexed why it turns so easy and doesn't return when you let go of the clutch lever. I have read that this has happened to other but no one has posted a fix.

Please help.

 

I hope it's not what happened to me when I had almost the same issue. If it's the same set-up as the DS you may have broken one of the teeth off of the actuator arm or the actuator rod. I've done both while running TVI 80% springs. The arm is what pulls the clutch basket out when the rod turns via the lever. At different times I sheared two or three teeth off each of those.
Hope that helps some. Good luck with it.