After installing a new clutch cable (the orignal cable broke) I had trouble setting up the cable tension and lever position - either the clutch would not engage fully or it would not disengage fully. I was able to get it setup close, but not perfect. After just a few minutes of riding, the engagement lever became loose and failed to disengage the clutch. With the engine hot, you could rotate the engagement lever freely with your hand instead of there being some sort of spring like tension. When I got home and the engine had cooled, the engagement lever seemed to be tighter, more like it should be. However, when I tried to rotate it, I could hear and feel the shaft grinding, like the splines were stripped or something. I think the shaft may be bent.

The clutch itself seems to be fine. I was able to ride without using the clutch to shift.

The DS is unreliable and will be for sale...

 

is this the only problem you've or is it just one of many? because before i bought mine i asked alot of questions on here before i bought it and the only thing anyone told me they had trouble with was the chain roller,which i replaced this weekend.the new roller is as hard as a rock and was origanally made for a 185s back in the 80s.my dealer has his bike lowered for flat track and TT and has been running one on his bike all year and is still in perfect shape.

 

He has had many, many problems. I have never seen or heard of a person having so many problems with a quad or any vehical for that matter. I personally think he is the type of guy who can destroy a brand new crow bar. I agree with riding hard...just dont beat the s**t out of it.

 

Scooby you should sell you self as an independent test engineer for ATV’s. I will find the weak part on your ATV.

 

LOL. It turns out to be no big deal. I removed the clutch cover after draining the coolant and oil and found nothing broken. The problem was that the bearing that holds the clutch actuator had popped out of it's housing while the clutch was hot. I think all I need to do is heat the bearing up and re-seat it.

 

All fixed now, just hope that bearing NEVER pops out again! I had to remove the clutch pressure plate to have better access to the bearing so I could re-seat it.