clutch help needed

[gwcrim]

Redid the clutch on the 02 250.  Magnum basket, Tusk plates and cable.  After assembly, it seems like the cable is too short.  There is no adjustment available and the clutch is slipping a bit at high RPM on pavement. 

Might there be something I put in backwards?  Any ideas?

[DoldGuy]

If you put the shim washers in incorrect it can give the symptoms described. The magnum basket, did you have to install the ring gear from the stocker?
DoldGuy

[81cr450]

could be missing a plate? you start with a friction & end with a friction.

No adjustment available in the cable & the perch ?

Double check that you got the correct basket maybe ?

[gwcrim]

Washers on either side of the basket, right?  That's how I did it.

The clutch arm engages the clutch at 1-2 oclock if you are looking down from the side of the bike.  I had to grab it with channel locks and twist it forward quite a bit to get the cable on and figured I might have this issue.  Or could the Tusk cable be the culprit?

[gwcrim]

The collar that goes between the clutch plate and the rod is cupped.  The open end faces out?

[DoldGuy]

Washer on the backside & inside of the basket. Should NOT have to grab the clutch arm to install the cable. Install the cable on the clutch arm first, then attach the cable at the lever. If the cable does not have enough slack, either it is the wrong cable or "something " is allowing the pressure plate to move closer in. There should be 8 fibers & 7 steel plates. If the cable is too short it could cause the slipping.
DoldGuy

[gwcrim]

Know what I did.  Left out the throw out bearing.  Can't find it to save my life.  Hope I can get one QUICK!

[gwcrim]

ok heres the final answer.  It was the ebay clutch arm.  Put the old one back in and we are good yo go...  except that it is pretty worn.