Okay,
here goes my dilemma. I put everything back together and notice that I can't squeeze the clutch lever without maybe using a ton of force which I don't want to do. I am not sure what to do to get the clutch lever to move. I am sure there is something I am missing procedure wise, but all the parts are back in properly as far as that goes. Anyone that has replaced clutch plates or springs and dealt with this please help.....thank you, JIM

 

Did you adjust it from inside the crank case?

There is an allen screw that you can adjust it with on the hydrolic ones.

 

lol....I figured out the problem....kind of embarassing, but if it helps someone in the future it is worth looking like an idiot. I had a hunch that the only thing it could be was the little check ball from behind the pressure plate/release collar assembly. The check ball is like 8mm and works with the push rod to work the clutch via the slave cylinder on the right side of the crankcase. I pulled the clutch cover, pressure plate off and sure enough the check ball had fallen on the ground underneath the quad while I was tapping the pressure plate onto the shaft. So, there it is....problem solved.......major pain, but I learned a lot and have the quad back together....even took it for a spin around the culdesac. The shift shaft was replaced with a new material, you can tell right away. As soon as I get the pics developed, I will post for you all to see some of the process and compare the shift shafts............JIM

 

Even the best of us have done that one. This is a good post, if you squeeze that lever a bunch of times without the ball in place and it gets really hard to pull the lever STOP! If you pull hard you will break the clutch slave cylinder. Don't feel too embarassed I have seen that done by some pretty keen mechanics, I won't mention any names Mr. Rubicon in Lake Ohlins.

 

lol....exactly, I broke the slave cylinder! It broke just on the lip that holds back the snap ring. Looked like a rim of a cup that broke off almost perfectly circular. I need an idea of the easiest place to get a replacement slave cylinder now.....any help is appreciated..........JIM