Dyna Ring Hell (SOLVED)

[sped66]

Installs in minutes... MY ASS.
I've had this thing apart & back together a half dozen times over the course of 3 days. Checked parts diagrams, re-read instructions, searched the forum & web, constantly checking the online kdx manual..... I've convinced myself I have everything in there the way it's supposed to fit & in the correct order. And yet, I can't attach my freaking clutch cable no matter how loose I adjust it.
Here is the actuator at rest:


And here it is when it reaches it's limilt:


I know this is wrong but if I try to correctly position the actuator while installing the clutch cover, the cover doesn't want to seat. You can see what Tedh98's looks like HERE. I'm on the verge of losing my temper in a really bad way.
HELP!?!

[Mr. Wibbens]

Do you have your clutch lever disconnected?

If not just remove the pivot bolt, that'll give it enough slack

[sped66]

Thanks Wib, I tried all of that yesterday. The photos were taken without any thought to what you guys might look at beyond the actuator.

I should clarify. The actuator positon is incorrect, no? I might force the cable to just barely reach, but what good would a fully taught cable do me?

[Mr. Wibbens]

Removed part of my post, it was wrong

Actuator looks about right to me, but maybe a little off ?

[Mr. Wibbens]

and you have this loosened?

[sped66]

IF I loosen everything as far as I can & take the clutch perch off the handlebars, it'll reach. But the actuator is pulled 100% tight. It wasn't like this at all prior to the Dyna Ring install.
I'm at wits end. I'm sick of disassembling/reassembling this thing. Something has to be wrong but damned if I can figure it out.

[Mr. Wibbens]

Washer on actuator?



I'm not least surprised all the trouble folks have had, KDX clutch is really finicky, least mine has always been

[sped66]

Washer on actuator?

It's there. (Also edited my previous post a bit.)

[SS109]

Just an FYI, your cable will always be tight. There will be no slack when adjusted properly.

[sped66]

I'm real close to making a video of me putting my clutch together. Maybe someone can spot something I'm doing wrong.

[Mr. Wibbens]

Try taking the washer out?

[SS109]

Try taking the washer out?

+1

[sped66]

I thought about that, by I have reservations about removing something that's supposed to be there. I'm putting together a short vid. If nobody spots anything suspicious after posting it, I'll try removing the washer. Btw, which washer do you mean? There are several.

[SS109]

The washer on the actuator is there only on an "as needed" basis. My bike doesn't have, or need, one.

[Mr. Wibbens]

The washer on the actuator is there only on an "as needed" basis. My bike doesn't have, or need, one.

Mine either

[Mr. Wibbens]

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I thought about that, by I have reservations about removing something that's supposed to be there. I'm putting together a short vid. If nobody spots anything suspicious after posting it, I'll try removing the washer. Btw, which washer do you mean? There are several.

Sometimes there's a washer behind the actuator shaft and sometimes not

[David_L6]

Have you called Revloc?

I don't know where the problem is on your bike but I didn't have any trouble at all on my 2000 KDX200. When I installed the Dyna Ring that was my first time being inside of a Kawasaki clutch (been inside of Hondas plenty of times). The Kawasaki clutch was different than I was accustomed to but I just followed the instructions that came with the Dyna Ring. The Dyna Ring install in a KDX sure seems to be hit and miss. Some people have no trouble and some have a lot of trouble. I'm guessing that there are some pretty liberal tolerances in the KDX and the Dyna Ring that stack up against the people that have had / are having problems.

[Mr. Wibbens]

Just an FYI, your cable will always be tight. There will be no slack when adjusted properly.

yup

[sped66]

Wibs & SS109 are both on "E" bikes right? If that makes any difference.
Mine does indeed have the washer behind the actuator shaft. As for my cable, I'm not looking for the recommended slack called for in the manual. I'm looking to make my clutch lever work at all.
But here's the video. I can take criticism if you see me do anything stupid.

[youtube][/youtube]

[SS109]

What is the big red arrow pointing at? If that is normal for an H series then never mind. As for the actuator washer, it is "as needed" for E and H series bikes IIRC.