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Discussion Starter · #1 ·
First a quick back ground. I have a 2006 Foreman ES and felt it was shifting a bit too hard. I decided to adjust the clutch, and found the clutch adjustment bolt to be VERY difficult to turn. I attempted to turn it until I felt resistance, but I basically had resistance the whole time. After struggling with it for a while, I managed to turn it counterclockwise until it stopped then came back a quarter turn. I then started the quad and shifted it into gear and it wouldn't move. I figured I had over adjusted the clutch bolt. I went to adjust it further, again with much resistance, and then one of the tips broke off the bolt:angry:. I couldn't adjust it, and my quad wouldn't move. So, I pulled off the front case cover to replace the clutch adjusting bolt. I didn't notice anything out of place while I had it apart, so I installed the new clutch adjusting bolt and put it back together. This time, the adjusting bolt turned nice and smooth. I turned it counterclockwise until I met resistance and then backed it off a quarter turn. I filled the quad with oil and started it up.

I shifted from N to first gear using the ES button. It indicates 1 on the readout and I can feel the bike kind of lurch like its going into gear. I give it some throttle and NOTHING:rant. I shifted down to Rev and same result, nothing. Sooooo......help??!! Please...
 

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Discussion Starter · #4 ·
It has 2000 miles on it. I had changed the oil recently, and it was running fine. I just felt it was shifted a bit hard which is why I figured I'd just adjust the clutch. I probably should have left well enough alone. Too late. Anyway, like I said earlier, the clutch adjusting bolt was all but frozen. I basically turned it fully clockwise until it stopped, then back counterclockwise till it stopped. It was VERY hard to turn. I then backed it off a quarter turn and...nothing. I'm wondering if I overadjusted it one way or another??? The adjusting bolt spins smoothly now in both directions. I just turned it counterclockwise until it stopped then back a quarter turn.
I have tried backing it out further and even tightening it further...still nothing! It's acting like the clutch isn't engaging at all?? I could pull the cover back off but I'm not even sure what to check?? Any other thoughts...anyone...
 

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Discussion Starter · #6 ·
If I pull it back apart how should I check it. Another words, should the clutch spin, can the plate be miss aligned... You mentioned something pushing on the clutch thats keeping it disengaged. Can you better explain how its supposed to function properly? (adjusting bolt, ball retainer, lifting cam, etc). Thanks..
 

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Discussion Starter · #8 ·
Helmut,
Thanks A LOT for the explanation, I think you did quite well, and that helps me a bunch. I'll open it back up, hopefully tomorrow, and give it a look see.

Another question, when I pull the front case cover, again, will I be able to spin the clutch assembly? Another words, what should be spinning freely so I'll know if something is stuck.

Thanks again!
 

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Discussion Starter · #9 ·
Oh yeah, would you mind explaining how the centrifigal clutch works with the regular clutch pack? At least that's what I think I'm looking at....
 

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Discussion Starter · #13 ·
EXCELLENT explanation, again much thanks.:bowdown:

You mentioned since I didn't have the clutch off, that you're guessing it's a problem with the adjusting screw and/or plate. That makes sense to me. Since I just replaced the bolt, is there a proper way to make an initial adjustment or zero point with the adjusting bolt and plate? Or would it hurt if I turned the adjusting screw clockwise until the stop?
 

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Discussion Starter · #16 ·
O.K guys, an update. I pulled the front case cover, again. I can't seem to find anything wrong or broken. Here's what is happening:

The atv is in Neutral, I can spin the "change clutch" counterclockwise which inturn spins the centrifugal clutch outer drum clockwise. I cannot spin the change clutch clockwise. I believe this is normal per your (Helmut) explanation with the atv being in Neutral.

The change clutch discs/plates are loose...not engaged or squeezed together. Is this normal? Again, the atv is in Neutral so I'm thinking that's ok.

Thought...is it possible that while using the ES shift buttons maybe the atv wasn't shifting into a gear completely? It did indicate a different gear on the display...i.e. I down shifted to Rev and 'R' showed up on display. Same as when I upshifted..'N' , then '1', then '2'. Does the display coincide with the actual gear position via the transmission or does it receive it's position elsewhere? (maybe a low battery?)

Also, can I use the manual shift selector with the front case off? If so, if I shift into first gear, would the clutch discs/plates be compressed?

I'm grasping here....
 

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Discussion Starter · #18 ·
OK...cool, we're on to something (actually, you're on to something...I'm just along for the ride)

I think your assesment of turning the adjustment screw too far is right on.

So, how to remedy my situation... Should I remove the 4 bolts and lifter plate? Or is there something I need to pry loose or realign? You mentioned the center of the clutch being pushed in too far, any idea on how to unpush it?
 

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Discussion Starter · #21 ·
OK...thanks. I'll give it a shot.

Can I do all this without removing the centrifugal clutch? Also, will I need any special clutch tools?
 

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Discussion Starter · #23 ·
I do have an impact gun and some gloves...I'll give it a go. Unfortunately, I gotta break for dinner with the neighbors:angry: Hopefully I'll get back to it tonight, if not tomorrow.

Helmut, again bud, thanks a million. I sincerely appreciate the time and effort you're putting in to help me.
 

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Discussion Starter · #25 ·
Will do, thanks again. Maybe I'll get lucky. Also, just to make sure I'm clear, the atv is in Neutral. Even with it in Neutral, the clutch plates/discs should be tight/engaged...right?
 

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Discussion Starter · #29 ·
HOMERUN!!:happy I was able to pull the the change clutch bolts, lifter plate and springs without having to remove the centrifugal clutch. I could then grab on the pressure plate 'threaded columns' that come through the center clutch plate and basically wiggle it while pulling forward. Sure enough, the pressure plate with the clutch discs were kind of hung up and after some wiggling, they all came forward nice and tight. You're (Helmut) assessment was once again right on!

Since you didn't take the clutch apart, I don't what would have caused this. Maybe you turned the adjusting screw too far and it pushed the center of the clutch in too far and somehow one of the discs or plates got hung. Just a guess, but that's all I can figure.
A quick recap, this all stated with my clutch adjusting screw/bolt being extremely difficult to turn and my atv shifting kind of hard. I figured I'd just turn in completely in one direction and then the other to try and work it loose. Unfortunately, as Helmut suspected, I turned it too far and pushed so hard on the lifter plate that is pushed the pressure plate back too far and it got hung up. When my atv wouldn't move/pull, I tried adjusting the clutch screw more and broke one of the tangs. I pulled the front case cover to replace the adjusting screw and buttoned it back up. Still wouldn't move:angry: That's what brought me to this tread and the above solution. So....Now I have the clutch working properly and a new adjusting screw/bolt turning nice and smooth. My atv shifts AWESOME!:lol: All thanks to the wonder folks on this forum with quick responses, and excellent detail.

Thanks again to all....Especially Helmut!

-Steve
 
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