HELP! Banshee clutch push rod is stuck

[Jonathan clark]

Okay so I put my banshee together and it ran then the clutch wouldn’t pull in (it was stuck) and I took the clutch apart and I was able to get the ball out with a magnet but not the clutch rod, it is stuck and won’t come out with the magnet. What can I do to fix this? I really don’t want to split cases. Is there any way to fix it without splitting cases??

[JerzOutlaw350]

  With the clutch taken apart now does the clutch lever pull in ? If it does then have someone pull the clutch lever in and release the clutch lever and then look at the clutch rod and see if it’s moves in and out. If it does then pull the clutch lever in and that should make it clutch rod move outward then reach in with a pair of needle nose pliers and pull the clutch rod out or you can also use a piece of 5/16 rubber hose and use it to remove the clutch rod .

[Jonathan clark]

No the clutch lever pulls in very little and it’s very stiff, even with the clutch taken apart. This makes me think the rod stuck. I can check again tonight to make sure 

[JerzOutlaw350]

   What you need to do is disconnect the clutch cable from the clutch release lever (the lever that’s down on the engine under the left carburetor) to to release the tension on the clutch release lever. Then check to see if the lever moves left to right. You can also try wiggling it left to right and at the same time try getting the clutch push rod out with the magnet as you are wiggling the lever. If the clutch release lever doesn’t move then remove the bolt and hold down bracket and then release the spring and try pulling lever up. Just be careful because there is a seal and a bearing under the lever. 

[Jonathan clark]

What should I do once the clutch release lever is out of the bike ? Has grinding the part of the rod that’s sticking out ever worked for anyone ?

 

[JerzOutlaw350]

 Take the clutch release lever and look at it for any type of damage. If there’s no signs of damage then put it on the side for now. How much of the clutch push rod is sticking out? 

[Jonathan clark]

no damage on the lever. And it looks about half an inch sticking out 

[JerzOutlaw350]

  Get yourself a good pair of vise grips and try to clamp it on what is sticking out. Try to lock the vise grips on as tight as possible then try pulling it out and wiggle it as you are pulling it.  
 
  A few months back I was working on a neighbor’s Banshee with a clutch problem that was almost similar to your problem and I did this to get the clutch push rod out. 

[Jonathan clark]

Just making sure, I don’t think vice grips will fit down in the clutch release lever hole.  And once I get it out a little bit do I cut it ?

[JerzOutlaw350]

  What does it look like when you look into the mainshaft where you have to slide the clutch push rod and clutch ball? 

[Jonathan clark]

All I see is the clutch push rod down there, I was able to get the ball out with a magnet 

[JerzOutlaw350]

  If you push on the stuck clutch push rod does it move inside the Mainshaft?    It’s more than likely that the end of the clutch push rod that makes contact with clutch release lever is mushroomed. If the clutch push rod is severely mushroomed then you will need to split the cases to get the clutch push rod out. 

[Jonathan clark]

Shoot I think it’s mushroomed, is there anyway to avoid splitting cases ? Dremeling the mushroomed part?

 

[Jereme6655]

23 hours ago, Jonathan clark said:

Shoot I think it’s mushroomed, is there anyway to avoid splitting cases ? Dremeling the mushroomed part?

 

Why are you so worried about splitting the cases? They split too and bottom….if you flip it upside down, you don’t even need to remove the top end…….ive seen guys replace trans parts in campground sites in just a couple hours start to finish….