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Discussion Starter #1
Hey guys, I`m new on here looking for some help. Clutch went out, replaced with a Tusk kit with springs. Soaked the fibers after putting it back together I cant pull the lever in at all. It`s not an adjustment problem, guessing I put something together wrong. Any help would be appreciated.
 

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Welcome to the forums! My bet is you didnt get the leverage arm hooked on the clutch push rod. If it dosnt hook on it right nothing will move. If this was the case without the cable attatched you still wouldnt be able to move the leverage arm. If you can move it then its a cable problem or clutch perch or adjustment problem. My .02
 

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Discussion Starter #3
Yeah iv been messing with it since i started this thread and thats what i discovered. Problem is everytime I try to put the cover on the push rod moves back and the leverage arm wont hook on it. Is there supposed to be play in and out on the pushrod?
 

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Yes. You need to start with the arm turned toward the back of the quad. Then as you push the cover on move it toward the front of the quad(with end pointed in). It should hook and stay in place at that point. The play in the push rod you will feel in the arm now. At that point your good.
 

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Discussion Starter #5
Is there a spring or something im missing behind the pushrod? Because I cant get it lined up perfectly to keep it from pushing it back. once its pushed back it stays back and wont hook on the leverage arm.
 

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Not a spring on any of them i have pulled apart. I have never had one not hook right on before.
 

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There is a return spring on the leverage arm down at the bottom. Is that in and the leverage arm in right? Maybe if that came out if its alignment hole it could move enough to not catch the push rod?
 

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hold on..... your telling me the pushrod goes on the outside of the pressure plate not behind it? Well, no f*#!ing wonder we cant get it!
No no no! I was thinking wrong! You have it right!
 

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Discussion Starter #10 (Edited)
Ok,lol! I was wondering how that would work. So anyway, the leverage arm spring and arm is in correctly. I just don't understand how to get the cover on without pushing the pushed in then the leverage arm won't reach it. I know you probably can't understand what I'm talking about without seeing it. It's really starting to tick me off.
 

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Man you got me stumped. Did you make sure you have all the frictions and steels in and in the right order? Same amount of both from your tusk kit to the stock ones? You tightened the clutch spring bolts down till they stopped turning and just a tad more? Keep the language to a minimum here. We try to keep the place kid friendly. Were not prudes or anything i just figured i would give you the heads up.
 

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Discussion Starter #12
Sorry about the language, I'll clean it up. Anyway the friction plates and steels are all in correctly and the right amount. I'm just at a loss. I've watched YouTube videos and they all just stick it right on. I don't know what I'm doing wrong. Thanks for trying to help me.
 

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No worries man! Take some pictures of stuff. Maybe that can help?
 

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Discussion Starter #14
Well, I got it put back together with the help of a strong magnet. Not sure what I was doing wrong but at least its together now.
 
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