giantragingmidget

i just went through my cases to put a new crank in. everything seemed to go fine. we got it back together and the clutch was slipping. it was the stock clutch so i just put in a new dirt digger. when it was done it seemed to "walk" ahead with the clutch pulled in and seemed to shift hard. talked to some people and they said that seemed normal for a new clutch-(needs to wear in). everything else seemed fine so i loaded it up and drove over three hours to silver lake sand dunes. rode for two hours-clutch problems!! when we tore it down for inspection we discovered the clutch lever assy. had been installed 180 degrees off-(don't know how it happened-didn't know it could!!!) when we did the crank. the half moon machined surface was NOT what the clutch rod was riding on-it was riding on the unmachined flat side! needless to say that created a ton of pressure on all that stuff in there thats why it shifted so hard. enough of me babbling-anyway check that clutch lever assy. to make sure it is properly installed. trust me if its not fix it now before you have the problems i did. it requires motor removal and splitting the case!!!

FIRST OFF IF THE CHOKE DOESN'T STAY OUT ON ITS OWN YOU SHOULD REPLACE IT. DID YOU HAVE THE CASE SPLIT? IF SO DID THE KICKSTART SPRING GET PLACED IN THE PROPER POSITION DURING REASSEMBLY?

I WAS AS LIBERAL AS I COULD BE WITHOUT IT SETTING UP BEFORE I COULD MATE THE HALFS-NEVER DONE A LEAKDOWN TEST BEFORE HOW DO I DO IT?

YES BOTH CRANK SEALS WERE CHANGED-I WILL CHECK THOSE OTHER ITEMS YOU SUGGESTED THANKS

I JUST GOT DONE REBUILDING MY BANSHEE FROM THE GROUND UP-ANYWAY I PUT A CRANK IN IT AND REBUILT THE TOP END-FIRED UP GREAT-IT FOULED THE LEFT SIDE AFTER A SHORT TIME RIDING SO I THOUGHT IT MUST HAVE BEEN ASSEMBLY OIL THAT FOULED IT-CHANGED PLUGS AND IT WAS A LITTLE BETTER BUT NOT RIGHT-I PULLED THE CARBS OFF AND FOUND THE LEFT SIDE NEEDLE JET WAS NOT FULLY SEATED IN THE CARB. IT WOULD NOT FULLY SEAT FOR SOME REASON SO I CHANGED THE NEEDLE JET SO IT FULLY SEATED. PUT CARBS BACK ON AND IT STARTED UP AND IDLED GOOD BUT AFTER A SHORT RIDE IT WOULD NOT GET OUT OF ITS OWN WAY. PULLED PLUGS AND RIGHT SIDE WAS BLACK AND LEFT SIDE WAS WHITE! ANY THOUGHTS OR SUGGESTIONS WOULD BE GREATLY APPRECIATED I HAVE A SILVER LAKE TRIP IN TWO WEEKS THANKS