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clutch shim installed

Discussion in 'How-To' started by lee, Aug 8, 2009.

  1. lee

    lee Well-Known Member

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    for those of us with 05 bikes (not sure about other years), especially if you have the Bandit clutch, you need to do this to a) correct the alignment between the motor sprocket and clutch pack, and b) to help the scraping of the clutch housing against the inner primary - remember Jakes thread.

    Here is a pic of the misalignment without the shim. It looks in the pic like the straight edge is against the inner hub - it isn't.

    [​IMG]

    Here is a pic of the shim and the shim in place. You can also see the scrape marks in the second pic.

    [​IMG]

    [​IMG]

    Here is what the alignment looks like after the shim is in place - still not perfect but better. I should have stuck a feeler gauge in there to measure it but forgot.

    [​IMG]

    I also used the tool I made by bolting together a friction plate and a steel plate - worked a charm and Al, left no marks on the hubs at all.

    [​IMG]

    and here is the fluids I'm now using - I thought it was about time we had another oil thread!

    [​IMG]

    I also pulled the stator off and it was full of tiny shavings - see Jakes pic - it was exactly the same and that is a bastard to clean because, of course, its magnetic.
     
  2. alhall88

    alhall88 UAW

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    Good job Lee, the tool was a good idea and glad it worked out for you. I wonder how much more it could be shimmed out before it would start rubbing the outer primary. Funny thing is that on a belt drive system this alignment must be within .010 but on a chain drive it can be a mile off.
     
  3. BBChopper

    BBChopper Supports 2 Disabled Vets
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    NiCe!!!!::cheers::2thumbs:
     
  4. Gas Man

    Gas Man Cool isn't cheap
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    I was wondering the same thing Al. On chain vs belt
     
  5. lee

    lee Well-Known Member

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    I thought I saw somewhere that the tolerance is 0.030" but it was a lot more out than that. I thought that with the outer primary but I would hope there was enough clearance for that - I guess also that the more shimmed out it is the more stress there is on the transmission main shaft perhaps.
     
  6. surferdude

    surferdude dry docked

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    Hey Lee .... did you order the shim from Bandit? :confused: :job: :up: :D

    thanks
     
  7. lee

    lee Well-Known Member

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    no - I got it from Nelson - its a BDM part. Costs about $3 - I had to pay $27 for shipping!!
     
  8. Firestream

    Firestream Member

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    For those of you that already have the shim, you may want to check it for damage the next time you have the basket removed. I have had some significant vibration develop and after checking all the usual suspects, I checked the primary sprockets for alignment, even though I knew I already had the shim installed. Well, I found the clutch sprocket to be too deep (.034), as if I had no shim in place, so I removed the basket and pulled the trans seal and found the shim damaged. Perhaps when BDM changed their torque spec from 80 to 100 ft lbs, it crushed the shim toward the trans mainshaft bearing. The tech told me their recommended process is to torque the clutch hub nut to 150 ft lbs and then back it off and re-torque to 100 ft lbs. I purchased one from the dealer along with a new trans seal and test fitted the single shim. Well, Like lee it still didn't align properly. I ended up finding the exact same shim at Ace Hardware in their specialty section. The shim has a 1" center hole and they cost .50, so I bought several to keep around. I checked the dimensions with a dial caliper and they exactly match the BDM part. So, in order to establish correct alignment, I had to file two of them to a slightly thinner thickness and trial fit them (several file and test fits) until I had perfect alignment. I installed with the filed sides facing each other and installed the new trans seal and re-assembled the sprockets, chain and clutch pack. I have not fired it up yet as I'm waiting for a balancer ring to be made by balancer masters for the Bandit pressure plate. Balance Masters now makes a balance ring for the front sprocket (I sent them my front sprocket to pattern a new part) which I installed upon assembly after shim install. Once I get the clutch part and install, I'll post pictures and see if they work as designed.
     
  9. bdmridgeback

    bdmridgeback Low Down Chop Shop

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    Your right Firestream, BDM had a issue on the first bikes that they started putting the shim in from the factory. It seems that the shims would compress under torque of the clutch nut and "thin out" over time. When I bought my shim from BDM, they had just came out with a hardened shim that supposedly won't do that. The day I stopped in to order the shim for my Bandit Clutch, The Trike Haus had a BDM bike in there swapping the shim out due to a vibration in the driveline. He had the stock shim laying there and it was "smashed". So I know I got the correct "good" shim and someday here soon I am going to pull my primary cover off for a inspection to check everything out now that I have put about 5000 miles on it.
     
  10. Firestream

    Firestream Member

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    Is there a different part number for the "hardened" shim. The one the dealer had in stock didn't have the typical hardened appearance. Mine had crushed so much it allowed the bearing carrier (bandit) to hit in the typical rub spot on the inner primary as the stock BDM carrier. I may try a specialty fastener shop and seek out a truly hardened washer/shim that has a 1" inside diameter and will fit behind the trans seal...
     
  11. bdmridgeback

    bdmridgeback Low Down Chop Shop

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    If you for sure want to order the correct shim, call Nelson at Wicked Bastard, we should be able to get you the right one.
     
  12. scubaman15

    scubaman15 Well-Known Member

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    Old thread but wondering how this worked out
     
  13. scubaman15

    scubaman15 Well-Known Member

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    Baker has them !!
     
  14. Bhojo

    Bhojo Member

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    Baker also has a hardened hub nut....about 6 bucks. The shim is about 3 bucks. My baker carrier just broke after 30k miles. I bought just the carrier plate from bandit and will use the stock clutch plate and spring plate. Maybe i'll upgrade the rest of the clutch later.
     
  15. battman

    battman New Member

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    did that clutch shim stop it from rubbing the inner primary wall cause my 05 chopper doing that, i think i might have to get me one. is there different size shims or just the one size cheers.
     
  16. gearheadjeff

    gearheadjeff New Member

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    I have an 05 BD chopper with clutch issues. Its a 117 ci S&S with a Baker 6 speed, not an open primary. When u first start it and put it in gear, the bike jumps and stalls, altho the cable adjustment is correct. im assuming it has the pushrod adjustment in the outside of the clutch basket, similar to Harleys. After a few times, you can get it freed up, but still wants to pull ya till its warmed up, then it seems fine. Where can i find the correct outer primary gasket, along with other parts...r brake pads, etc?
     
  17. woodbutcher

    woodbutcher Mr. Old Fart member #145
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    Kaptain Amerika has a lot of what you need at WildSteedWorx.com , he is a forum sponsoring vendor listed at the home page.
     
  18. francoblay1

    francoblay1 The Spaniard

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    Here ya go: http://www.bigdogbiker.com/threads/how-to-adjust-your-clutch-05-and-newer.2025/
     
    cdogg556 and kschopper like this.
  19. Th3InfamousI

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    Do we know when they came out with the hardened shim?

    Sent from my 831C using Tapatalk
     

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