I replaced the springs, frictions, and steels on my 85 Quadsport and must have done something wrong. The clutch is way too stiff and it won't disengage even with the lever pulled all the way to the bar. Could I have the clutch arm shaft in the wrong position? I searched the Quadsport mega-thread but came up empty. Thanks.

 

I took it back apart this morning and there is no way to get the clutch arm shaft in the wrong position. So it's something else. I took the plates out and put them back in just to make sure they were right. Still won't disengage and super stiff.

 

Did you try to adjust the clutch arm or the cabe adjustment I would def try those first before taking the case back off and I was wondering if you knew about the gears in the kickstart I have a 1985 230 and im trying to get the kickstart gears lined up

 

On a lot of multiplate clutches the back steel plate slides onto the part that is threaded for the screws. If the splines on this part don't line up with the clutch centre outer splines that back metal plate gets stuck (and probably bent) when you tighten the screws down that put pressure on the springs.

 

YZ guy, I tried the cable adjustment first. The problem is it takes dang near 2 hands to pull the lever towards the bar. Yeah I knew about the kicker gear, that one got me before LOL.

Merryman, I'm not sure what you are referring to but the steels and fibers slide in without any problem. The clutch outer pressure plate [the aluminum one] was the only other part removed beside the steels, fibers and springs.

I haven't done anything with it since I pulled the cover the second time. I'm starting to hate this thing. If this isn't enough I have a starting issue as well but am waiting to get the clutch figured out before tackling that problem.
Thanks for the help.

 

My mistake, I thought the clutch itself would be similar to the 230e but it isn't.

 

Thanks for the assist. Yeah the "e" is a centrifugal clutch.