Cannondaleriders

Hi guys, did a two and a half hour hare and hounds yesterday, and just when I wanted to push on in the last half hour, I noticed that my right boot was looking slightly wet, and not because we'd been running through any water....

Anyway, I kinda limped round for the last 15 minutes, but I did at least take the flag. I had to push the quad across the finnish line because the clutch lever failed.

Anyway, fast forward 24 hours and I've started to take the bike apart. I took a line to avoid a nasty lump in the track which meant's I brushed past a bush on one lap, it was in hindsight quite a solid hit which was taken by the top of the radiator:



Now my question is, best to junk this right? the top pipe has had a whack and there's a small dent to the top of the rad right on the corner. I'm going to get new hoses made up even though they don't appear to be split though one was bulging slightly, as I've threatened to do this in the past, I've finally got an excuse! There was at least quite a bit of coolant still in the rad and hoses when I pulled it all off today, which is a huge relief.

The clutch has been a bit of an ongoing saga, at the first MX of the season it needed some adjustment, no problem. Did another mx a few weeks later and it was fine. Got to the last 10 minutes yesterday and it wouldn't disengage, transmission had plenty of oil, and when I found neutral and pushed it across the line I adjusted it further and could finally just about get it to release in gear. Anyway, more exploration today reveals this:



The clutch fluid itself was kind of brown, and while there was plenty of it, it wasn't doing what it should do. Again, I'm guessing it's time to junk this and get a new one?

As ever, appreciate your input, felt slightly deflated yesterday even though I got to the flag.

Check that the red knob on clutch master is pushed on the halfmoon post flush. If it comes off to far clutch will slip because it wont self adjust.

I had to have it wound in to the max to get it to work, what's the difference between the black ones and the bronze apart from the color? are there any mods that have been done on the rad front or is the stock item suitable at doing a good job?

The red adjuster knob is only for adjusting the angle of the hand lever, and not for compensating for clutch wear. That knob does not adjust the clutch itself, and no matter where the handle angle is set, the master cylinder must get a full stroke of the plunger left-right-left.
If that red knob is turned all the way IN, the center steel "D" shaft with dive to the right and inset itself -- and will no longer be flush with the left edge of the red knob. In that position, the master cylinder will NOT get the full backstroke, and the clutch action will barely even move the pressure plate.

Your machine might only need a few clutch plates to build back up the stack thickness, or a center-
screw adjustment behind the clutch cover.

But at the handle, as C27 mentioned, the plunge rod must remain flush with the left edge of the red knob.

Well, after much coaxing, the quad fired back into life! this machine seems to be more robust than my yamaha warrior!