How to adjust your clutch - Page 2

Raywood · 05-04-2008, 10:49 PM

Quote:

Originally Posted by TCALZ06

Great write up I just used it after dealer F'd up my clutch adj on my 5k service

you might want to mention that the clutch adjusting cover spins off and I had to use a oil filter wrench with a adj rubber band to get it off.

Yeah, that SOB gets tight!!! I won't mention that I couldn't get mine loose but the mechanic at the dealer turned it right off........... Won't tell you SHE was a small little girl!!!

gooddoggie · 05-04-2008, 11:17 PM

Also another method to remove the clutch adjusting rod cover is to pick up one of those rubber tipped door stops at the hardware and saw or grind off the screw end flush that screws into the base board, then just place the rubber stopper end in one of the recess areas of the cover and tap lightly with a small hammer in a counter clockwise direction and it should come off easily, the rubber protects the chrome and won't do any damage. Don't forget antisieze when you reinstall it.

ramfl41 · 05-05-2008, 12:01 AM

Interesting thread...seeing that I just looked at it today about 30 minutes after my clutch cable broke! Clutch pull was gettin stiff then snapped and my lever was sittin on my grip. It's an '06 Chopper still under warranty - Any How-to threads with pics on handling this? Thx.

outlawcrewcab · 05-05-2008, 11:35 PM

will this work on my 02 with a 5 speed? guess i need to go look

outlawcrewcab · 05-06-2008, 12:46 AM

yep my 5 speed set up is not the same anyone know how to do it? i have the same problem with the bike hard to put in neutrul and its always feels like clutch is draging at redlight always moving forward

CURDOG · 05-06-2008, 02:20 AM

Quote:

Originally Posted by ramfl41

Interesting thread...seeing that I just looked at it today about 30 minutes after my clutch cable broke! Clutch pull was gettin stiff then snapped and my lever was sittin on my grip. It's an '06 Chopper still under warranty - Any How-to threads with pics on handling this? Thx.

Ram, if it's still under warranty why not let the dealer replace it and then you can adjust it properly if they don't. My cable broke with @ 4000 miles on my '06 Mastiff and the dealer replaced it.

surferdude · 05-06-2008, 07:50 AM

When I adjust the pushrod screw in until it stops and back off 1/4 turn the clutch does not engage and the clutch lever is really hard to pull ... what am I doing wrong? ... how tight should the pushrod be? I'm following the instructions but it doesnt' seem to work for me ... help

It seems that the clutch is not engaging all the way. Is the 05's adjustment different? I bearly got the bike back into the garage ... just rode about 20 feet and back into the garage to re-adjust but nothing yet seems to work ... I've adjusted it loose ... tight ... still hard to get it into neutral unless I turn it off and then it pops into neutral real easy. Could something come loose in the clutch housing?

lee · 05-06-2008, 12:39 PM

No the 05's are not different - when you turn the pushrod screw in do not do it until it stops i.e. do not force it til it won't go any more - just do it until you first feel the resistance - then back it out. Also make sure you leave about 1/8" free play in the cable.

Also with the 05's many of them had a pushrod which was too thick - you may need to get a replacement - Nelson (WB Cycles) will sort you out - costs about $35 I believe.

surferdude · 05-06-2008, 02:43 PM

Ok ... This is what I've done.
--- loosen the cable
--- adjusted the pushrod until I feel resistence
--- back off 1/4 turn
--- tighten the nut on the pushrod
--- taken the slack out of the cable ... not to tight
And I can barely get the bike rolling in 1st gear ... it can almost stay still in 1st with the clutch lever released.
Seems that I need to make some other adjustment ... any suggestions beside take it to a shop?

lee · 05-06-2008, 07:56 PM

sounds like you need to back out the pushrod some more - I had the exact same thing (best part of 2 complete turns out) before I bought a new pushrod - you'd best try that and get in touch with Nelson

surferdude · 05-07-2008, 03:07 PM

Quote:

Originally Posted by lee

sounds like you need to back out the pushrod some more - I had the exact same thing (best part of 2 complete turns out) before I bought a new pushrod - you'd best try that and get in touch with Nelson

Lee ... thank you!!!! I do have a question ... why doesn't the adjustment work as described at the beginning of the thread? And what is the difference of the new pushrod vs. original? And what exactly does the pushrod do? And is there a way to refine the adustment since you can't see what's being adjusted? Can you take the cover off to see the pushrod? Ok a lot of questions I didn't have two days ago. Thank you again ... I thought I would have to get a new 08 Bigdog Ridgeback ... oh well next time

Raywood · 05-07-2008, 03:18 PM

surferdude, your adjustment should work just like the first topic.

I would first make sure the rod is going all the way through the tranny and seating properly. Grease the rod real good, when you insert it most of the grease will be squeezed off by the seal so I shoot extra grease inside before inserting the rod (from inside the cover not outside).
As for how it works, the ball and ramp assembly inside the cover push the rod in and out about an 1/8th of and inch when you pull the lever. This pushs the rod through the tranny to the otherside and seperates the clutch and pressure plate pack.
When you do your adjustments all you are doing is determining how much push you will get on the other end. It's a simple adjustment so experiment with it but the guidelines above should work first time.
The adjustment on the downtube is only for the cable slack itself.
Pulling the cover off is easy and if you do pull it ensure there is plenty of grease inside the ball and ramp assembly but don't move anything around in there if you don't have a sense of how it goes back together.
It's all in the manual.

Good luck,
Ray

surferdude · 05-07-2008, 03:27 PM

Hi Raywood ... I did the adjustment just like the thread said in the beginning ... I re-checked and re-checked and it just would not engage ... the bike bearly moved ... I backed the pushrod 2 full turns like Lee said and the clutch totally engages ... that's why I'm a bit cornfused??? I understand what you are saying and that makes it more cornfusing that it doesn't work ... something else is out of adjustment. Would taking the clutch cover off make it easier to see what the pushrod is doing? And when replacing the pushrod can you just unscrew it and screw in the new one?
Thanks ...

Raywood · 05-07-2008, 03:39 PM

Sounds like your problem is you are backing off the pushrod two full turns.
Then manual states to back it off 1/4", that's only one quarter of an inch.
Here are some pics of the setup that I've posted on here before. Re do it using the 1/4" adjustment and see what you get.
Good luck,
Ray

lee · 05-07-2008, 07:37 PM

as I said before you need a new pushrod - you have the exact same thing I had - I needed about 2 complete turns out with my old pushrod otherwise the clutch would not engage but when I put my new one in it was 1/4 turn without adjusting anything else. Some of the 05 pushrods were too thick and get smoothed out - you will see what I mean when you compare it with your new one.

05-06-2008, 07:50 AM	#22 (permalink)
surferdude surferdude Join Date: Mar 2008 Location: Cottonwood Arizona Posts: 204 My Bike: 05 Bigdog Ridgeback My Biker Photos Rep Power: 1	When I adjust the pushrod screw in until it stops and back off 1/4 turn the clutch does not engage and the clutch lever is really hard to pull ... what am I doing wrong? ... how tight should the pushrod be? I'm following the instructions but it doesnt' seem to work for me ... help It seems that the clutch is not engaging all the way. Is the 05's adjustment different? I bearly got the bike back into the garage ... just rode about 20 feet and back into the garage to re-adjust but nothing yet seems to work ... I've adjusted it loose ... tight ... still hard to get it into neutral unless I turn it off and then it pops into neutral real easy. Could something come loose in the clutch housing? Last edited by surferdude : 05-06-2008 at 09:14 AM.

05-06-2008, 02:43 PM	#24 (permalink)
surferdude surferdude Join Date: Mar 2008 Location: Cottonwood Arizona Posts: 204 My Bike: 05 Bigdog Ridgeback My Biker Photos Rep Power: 1	Ok ... This is what I've done. --- loosen the cable --- adjusted the pushrod until I feel resistence --- back off 1/4 turn --- tighten the nut on the pushrod --- taken the slack out of the cable ... not to tight And I can barely get the bike rolling in 1st gear ... it can almost stay still in 1st with the clutch lever released. Seems that I need to make some other adjustment ... any suggestions beside take it to a shop? Last edited by surferdude : 05-06-2008 at 03:06 PM.

05-07-2008, 03:18 PM	#27 (permalink)
Raywood Bubbleheads Assistant Join Date: Apr 2007 Location: Bremerton, WA Posts: 5,701 My Bike: 05 BD Chopper My Biker Photos Rep Power: 5	surferdude, your adjustment should work just like the first topic. I would first make sure the rod is going all the way through the tranny and seating properly. Grease the rod real good, when you insert it most of the grease will be squeezed off by the seal so I shoot extra grease inside before inserting the rod (from inside the cover not outside). As for how it works, the ball and ramp assembly inside the cover push the rod in and out about an 1/8th of and inch when you pull the lever. This pushs the rod through the tranny to the otherside and seperates the clutch and pressure plate pack. When you do your adjustments all you are doing is determining how much push you will get on the other end. It's a simple adjustment so experiment with it but the guidelines above should work first time. The adjustment on the downtube is only for the cable slack itself. Pulling the cover off is easy and if you do pull it ensure there is plenty of grease inside the ball and ramp assembly but don't move anything around in there if you don't have a sense of how it goes back together. It's all in the manual. Good luck, Ray __________________ 2005 Big Dog Chopper Black & Chrome 56,000 miles as of today Tomorow will be different! Rode hard and put away wet!

05-07-2008, 03:39 PM	#29 (permalink)
Raywood Bubbleheads Assistant Join Date: Apr 2007 Location: Bremerton, WA Posts: 5,701 My Bike: 05 BD Chopper My Biker Photos Rep Power: 5	Sounds like your problem is you are backing off the pushrod two full turns. Then manual states to back it off 1/4", that's only one quarter of an inch. Here are some pics of the setup that I've posted on here before. Re do it using the 1/4" adjustment and see what you get. Good luck, Ray __________________ 2005 Big Dog Chopper Black & Chrome 56,000 miles as of today Tomorow will be different! Rode hard and put away wet!

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05-04-2008, 11:17 PM	#17 (permalink)
gooddoggie Member Join Date: Apr 2007 Location: Downers Grove Il. Posts: 111 My Biker Photos Rep Power: 2	Also another method to remove the clutch adjusting rod cover is to pick up one of those rubber tipped door stops at the hardware and saw or grind off the screw end flush that screws into the base board, then just place the rubber stopper end in one of the recess areas of the cover and tap lightly with a small hammer in a counter clockwise direction and it should come off easily, the rubber protects the chrome and won't do any damage. Don't forget antisieze when you reinstall it.

05-05-2008, 12:01 AM	#18 (permalink)
ramfl41 Member Join Date: Feb 2008 Location: Sarasota, FL. Posts: 57 My Bike: '06 chopper My Biker Photos Rep Power: 1	Interesting thread...seeing that I just looked at it today about 30 minutes after my clutch cable broke! Clutch pull was gettin stiff then snapped and my lever was sittin on my grip. It's an '06 Chopper still under warranty - Any How-to threads with pics on handling this? Thx.

05-05-2008, 11:35 PM	#19 (permalink)
outlawcrewcab Member Join Date: Apr 2008 Location: Ft Worth TX Posts: 133 My Bike: 02 pitbull My Biker Photos Rep Power: 1	will this work on my 02 with a 5 speed? guess i need to go look

05-06-2008, 12:46 AM	#20 (permalink)
outlawcrewcab Member Join Date: Apr 2008 Location: Ft Worth TX Posts: 133 My Bike: 02 pitbull My Biker Photos Rep Power: 1	yep my 5 speed set up is not the same anyone know how to do it? i have the same problem with the bike hard to put in neutrul and its always feels like clutch is draging at redlight always moving forward

05-06-2008, 12:39 PM	#23 (permalink)
lee Senior Member Join Date: Nov 2007 Location: Bristol, England Posts: 3,082 My Bike: 2005 Bulldog and 2002 HD Heritage My Biker Photos Rep Power: 4	No the 05's are not different - when you turn the pushrod screw in do not do it until it stops i.e. do not force it til it won't go any more - just do it until you first feel the resistance - then back it out. Also make sure you leave about 1/8" free play in the cable. Also with the 05's many of them had a pushrod which was too thick - you may need to get a replacement - Nelson (WB Cycles) will sort you out - costs about $35 I believe.

05-06-2008, 07:56 PM	#25 (permalink)
lee Senior Member Join Date: Nov 2007 Location: Bristol, England Posts: 3,082 My Bike: 2005 Bulldog and 2002 HD Heritage My Biker Photos Rep Power: 4	sounds like you need to back out the pushrod some more - I had the exact same thing (best part of 2 complete turns out) before I bought a new pushrod - you'd best try that and get in touch with Nelson

05-07-2008, 03:27 PM	#28 (permalink)
surferdude surferdude Join Date: Mar 2008 Location: Cottonwood Arizona Posts: 204 My Bike: 05 Bigdog Ridgeback My Biker Photos Rep Power: 1	Hi Raywood ... I did the adjustment just like the thread said in the beginning ... I re-checked and re-checked and it just would not engage ... the bike bearly moved ... I backed the pushrod 2 full turns like Lee said and the clutch totally engages ... that's why I'm a bit cornfused??? I understand what you are saying and that makes it more cornfusing that it doesn't work ... something else is out of adjustment. Would taking the clutch cover off make it easier to see what the pushrod is doing? And when replacing the pushrod can you just unscrew it and screw in the new one? Thanks ...

05-07-2008, 07:37 PM	#30 (permalink)
lee Senior Member Join Date: Nov 2007 Location: Bristol, England Posts: 3,082 My Bike: 2005 Bulldog and 2002 HD Heritage My Biker Photos Rep Power: 4	as I said before you need a new pushrod - you have the exact same thing I had - I needed about 2 complete turns out with my old pushrod otherwise the clutch would not engage but when I put my new one in it was 1/4 turn without adjusting anything else. Some of the 05 pushrods were too thick and get smoothed out - you will see what I mean when you compare it with your new one.