How to adjust your clutch - Page 4

Fibersnake · 05-11-2008, 10:10 PM

It is 1/4 turn (as Raywood and other pointed out) after all free play is taken out. Make sure that when you tighten the lock nut (6-10' lbs.) That you hold the adjusting screw to make sure it does not turn.

Cable slack is 1/16"

Below is from Section 4-2 out of the BDM 2005-2006 Service Manual

CLUTCH AD,JUSTMENT PROCEDURE
Perform the following clutch adjustment at all service intervals.
1. Support the motorcycle upright and level.
2. Slide clutch cable adjuster boot out of the way of adjusting hardware.
3. Turn adjuster to provide maximum slack in cable.
4. Loosen pushrod adjusting screw jam nut.
5. Turn pushrod adjusting screw clockwise to take up all free play in pushrod.
6. Turn pushrod adjusting screw counter-clockwise 1 /4 turn.
7. Tighten pushrod adjusting screw jam nut to 6-10 ft Ibs. Do not allow adjusting screw to turn while tightening jam nut.
8. Adjust clutch cable to provide 1/16" free play at clutch lever.
9, Tighten clutch cable adjuster locknut.
10. Return clutch cable adjuster boot to original position.

surferdude · 05-11-2008, 10:46 PM

Yup ... that's what I've done and on a worn out pushrod or broken something it won't engage the clutch. Lee had the same problem and like he had to do I had to back it out 2 1/4 turns before the clutch will engage ... I kept the allen wrench in the adjusting bolt to make sure it wasn't moving. I think I will go with the Bandit set up .... So in the next few weeks I'll get the parts and re-read the how-to ... Does anybody know why this is happening on so many 05's????

Fibersnake · 05-11-2008, 11:01 PM

Not sure what you mean by happened on so many 05. It has occured but I do not think it is a very big on-going problem, at least no more than any other years. Could be wrong but have had no issues with mine.

It may be just making sure that one does it often enough to keep up with the maintenance schedule and not letting it go and then have it more likely to fail. Should be checked and adjusted every 2500 miles according toe my O & M Manual or same time frame as oil and filters.

Gas Man · 05-12-2008, 05:41 AM

reason... fucked up carriers.

and on the freeplay once the clutch rod is adjusted... just make the lever hold a dime. Al taught me that trick... works great!

Ronbo · 08-05-2008, 01:31 AM

nice one thanks man

acutigerfan · 09-25-2008, 02:45 AM

Awesome info, bro!! Thanks a bunch...Saved me some headaches, money, and my ego....!! Hell, yea!!

waykool · 10-25-2008, 09:31 PM

Quote:

Originally Posted by tacoloco

My shifting was hard and finding neutral was difficult. After adjusting my clutch, my shifting is now smooth and finding neutral is a breeze. This is how I did it. After leveling the bike, slide the clutch cable boot to access the cable adjuster

Finally adjust your cable to give your clutch lever 1/16 of free play. Tighten the jam nut and slide the boot back in place.
Enjoy your smooth clutch. If this adjustment doesn’t do the trick for you, consult your near BD dealer.

After tightening the jam nut should Lok-Tight be used? I just got back from getting my dog serviced at Tampa Big Dog. They said that they adjusting the clutch and all seemed good when i left the dealership. But on my way home the clutch adjuster vibrated loose. This was not a good thing. When pulling off the highway onto the off ramp I noticed that I had no clutch. Almost rear ended the car in front of me and nearly got rear ended by the car behind me. Like I said, Not good. Didn’t have any tools with me so I adjusted it as good as I could by hand. Vibrated loose once more on the rest of the way home. Needless to say now its back to being hard to shift and I still cant get it into neutral.

lee · 10-25-2008, 10:28 PM

same thing happened to me recently. I just tightened it back up when I got home and its been fine. I doubt you should put loctite on it - I certainly don't. They probably forgot to tighten it properly after adjusting it.

waykool · 10-25-2008, 10:39 PM

Quote:

Originally Posted by lee

same thing happened to me recently. I just tightened it back up when I got home and its been fine. I doubt you should put loctite on it - I certainly don't. They probably forgot to tighten it properly after adjusting it.

Ahhhh.... I see. No thread lock needed. Thank you.

Raywood · 10-25-2008, 11:04 PM

Quote:

Originally Posted by waykool

Ahhhh.... I see. No thread lock needed. Thank you.

You expand the adjustere till you have 1/8" of slack/gap at the clutch handle lever. Take out a bit more if you like it snug.
This adjustment is only for the lever not the clutch although if there's too much slap you won't get full acuation of the clutch rod.

05-11-2008, 10:10 PM	#46 (permalink)
Fibersnake Sandbox Palace Deweller Join Date: Jun 2007 Location: Iraq via Eastern Panhandle WV Posts: 1,858 My Bike: 2005 BD Mastiff My Biker Photos Rep Power: 3	It is 1/4 turn (as Raywood and other pointed out) after all free play is taken out. Make sure that when you tighten the lock nut (6-10' lbs.) That you hold the adjusting screw to make sure it does not turn. Cable slack is 1/16" Below is from Section 4-2 out of the BDM 2005-2006 Service Manual CLUTCH AD,JUSTMENT PROCEDURE Perform the following clutch adjustment at all service intervals. 1. Support the motorcycle upright and level. 2. Slide clutch cable adjuster boot out of the way of adjusting hardware. 3. Turn adjuster to provide maximum slack in cable. 4. Loosen pushrod adjusting screw jam nut. 5. Turn pushrod adjusting screw clockwise to take up all free play in pushrod. 6. Turn pushrod adjusting screw counter-clockwise 1 /4 turn. 7. Tighten pushrod adjusting screw jam nut to 6-10 ft Ibs. Do not allow adjusting screw to turn while tightening jam nut. 8. Adjust clutch cable to provide 1/16" free play at clutch lever. 9, Tighten clutch cable adjuster locknut. 10. Return clutch cable adjuster boot to original position. __________________ Don't Piss on my back and telling me it is raining Last edited by Fibersnake : 05-11-2008 at 11:03 PM.

05-11-2008, 11:01 PM	#48 (permalink)
Fibersnake Sandbox Palace Deweller Join Date: Jun 2007 Location: Iraq via Eastern Panhandle WV Posts: 1,858 My Bike: 2005 BD Mastiff My Biker Photos Rep Power: 3	Not sure what you mean by happened on so many 05. It has occured but I do not think it is a very big on-going problem, at least no more than any other years. Could be wrong but have had no issues with mine. It may be just making sure that one does it often enough to keep up with the maintenance schedule and not letting it go and then have it more likely to fail. Should be checked and adjusted every 2500 miles according toe my O & M Manual or same time frame as oil and filters. __________________ Don't Piss on my back and telling me it is raining

05-12-2008, 05:41 AM	#49 (permalink)
Gas Man Custom doesn't bolt on Join Date: Apr 2007 Location: SE Michigan Posts: 10,636 My Bike: 2006 Big Dog Phoenix Chopper My Biker Photos Rep Power: 11	reason... fucked up carriers. and on the freeplay once the clutch rod is adjusted... just make the lever hold a dime. Al taught me that trick... works great! __________________ -Chris "Why pay somebody else to fuck up your bike?"

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05-11-2008, 10:46 PM	#47 (permalink)
surferdude surferdude Join Date: Mar 2008 Location: Cottonwood Arizona Posts: 204 My Bike: 05 Bigdog Ridgeback My Biker Photos Rep Power: 1	Yup ... that's what I've done and on a worn out pushrod or broken something it won't engage the clutch. Lee had the same problem and like he had to do I had to back it out 2 1/4 turns before the clutch will engage ... I kept the allen wrench in the adjusting bolt to make sure it wasn't moving. I think I will go with the Bandit set up .... So in the next few weeks I'll get the parts and re-read the how-to ... Does anybody know why this is happening on so many 05's????

08-05-2008, 01:31 AM	#50 (permalink)
Ronbo Always willing to Learn Join Date: May 2008 Location: Chesterfield Va Posts: 11 My Bike: 2006 Mastiff My Biker Photos Rep Power: 0	nice one thanks man

09-25-2008, 02:45 AM	#51 (permalink)
acutigerfan Junior Member Join Date: Jun 2008 Posts: 2 My Biker Photos Rep Power: 0	Awesome info, bro!! Thanks a bunch...Saved me some headaches, money, and my ego....!! Hell, yea!!

10-25-2008, 10:28 PM	#53 (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	same thing happened to me recently. I just tightened it back up when I got home and its been fine. I doubt you should put loctite on it - I certainly don't. They probably forgot to tighten it properly after adjusting it.