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How to adjust your clutch (05 and newer)

Discussion in 'How-To' started by tacoloco, Jan 2, 2008.

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  1. surferdude

    surferdude dry docked

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    Well ... got some bad news ... for me ... but obviously not the first ... I talked to Nelson and the guys at Strokers ... those guys are great ... they were busy yet had the time to "educate" me about the pushrod, clutch etc. I pulled off the primary inspection cover and did not like what I saw ... I did the 10k primary fluid change and now at 13k the fluid is all gray and something was grinding and wearing out. So far the bike is running good but sooner or later something will break or just stop working. I called the service guys in Prescott and they said that it should take about 2 hrs to replace the clutch carrier and put in a new clutch ... I would attemp to do it myself but I'm not that confident yet. I see that some of you have put in the Bandit clutch .... any other suggestions? :D Thanks ...
    Also since I'll have the clutch all apart what else should I be thinking about?
     
    #41 surferdude, May 11, 2008
    Last edited: May 11, 2008
  2. lee

    lee Well-Known Member

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    IF your clutch needs replacing, I would of thought the Bandit would be the way to go - there is a how to on here by Jake on installing the bandit - read it through a couple of times before you decide on paying the extra for someone else to do the work. I'm sure Jake will also help you out with any issues as he has done this already.
     
  3. Gas Man

    Gas Man Cool isn't cheap
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  4. stlmikie

    stlmikie I wish I had more money.

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    I quarter inch or a quarter turn?
     
  5. Raywood

    Raywood The Pirate
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    It's 1/4th turn but this is for the RSD set ups. Don't know what it is on your "OLD" system! :eek:

    :whoop:

    :cheers:
     
  6. Fibersnake

    Fibersnake Banjo Playing PsychoBilly

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    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.
     
    #46 Fibersnake, May 11, 2008
    Last edited: May 11, 2008
  7. surferdude

    surferdude dry docked

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    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???? :confused: :eek: :job:
     
  8. Fibersnake

    Fibersnake Banjo Playing PsychoBilly

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    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.
     
  9. Gas Man

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    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!
     
  10. Ronbo

    Ronbo Member
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    nice one thanks man
     
  11. acutigerfan

    acutigerfan New Member

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

    waykool Banned

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    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.
     
    #52 waykool, Oct 25, 2008
    Last edited: Oct 25, 2008
  13. lee

    lee Well-Known Member

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    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.
     
  14. waykool

    waykool Banned

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    Ahhhh.... I see. No thread lock needed. Thank you.:D
     
  15. Raywood

    Raywood The Pirate
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    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.

    :cheers:
     
  16. Keith S

    Keith S EHC FREE!!!!

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    Does anyone have the how-to for adjusting the clutch on the LSD models? Is the pushrod adjustment in the center of the clutch under the primary cover?
     
  17. pig pen

    pig pen Well-Known Member

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    yup. Most adjustment can be made on the cabel, 1/8 inch of play in lever.
     
  18. DRBarnhart

    DRBarnhart Insert title here...

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    The primary looks the same as a Harley which would mean your right, the adjustment is under the derby cover.

    The actual adjustment procedure will be the same from there.

    Dennis
     
  19. REMorris

    REMorris OK Rider Shakey

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    BDM dealership, Iron Lightning says the adjustment procedure for my 2009 Mastiff, is totally different than this procedure.

    So, if you have an 09 model, get the new instructions first.
     
  20. Eric

    Eric Banned

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    whats the differance????
     
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