BMX - Stolen Roulette freecoaster hub question

I am looking for a schematic or a stepbystep set of instructions on how to properly set a freecoaster hub. My customers' hub keeps locking up instead of 'freecoasting' and all the parts seem to be in decent shape however, I must be lame or something because I can't seem to get the adjustment right. It will either lock up or pedal 'normal' but he says it 'pops' when he tries to freecoast. Just throwing this out there -

Here are some tech videos to help out.

Adjustment

http://vimeo.com/4068746

Disassembly / Assembly

http://vimeo.com/4092351

Here is an explanation from KHE on why there is a popping noise when the rider stops pedaling in their freecoasters. I have the KHE Reverse 2 and it does it.

"The popping noise occurs when the clutch (driver-cone) disengage from the hub shell. The clutch has a raw / corrugated side, please take a metal file and remove any shape pieces for this raw side. Now regrease this side from the clutch and assemble the hub again. It should run without any noise."

Do your customers know HOW to use a freecoaster? There is a gap between engagement and dis-engagement. If you back pedal too far, it won't freecoast.

Do your customers know HOW to use a freecoaster? There is a gap between engagement and dis-engagement. If you back pedal too far, it won't freecoast.

I usually back-pedal a little right before i know i'm going to need it to disengage. Usually helps. Maybe give them that little bit of advice? A few friends of mine bought the Roulette, and they've had disengagement problems too.

I usually back-pedal a little right before i know i'm going to need it to disengage. Usually helps.

This.

This.

Is correct?

Yeah.

Thanks all - you've been a big help!