Need help

wolfen

wolfen

Member
I went to adjust the clutch which I have done thousand times on a Harley. This is the first time I`m attempting it on the big dog. I couldn`t get into neutral when I was at a stop. When I put into 1st. gear it would lunge a little. So I figured I would adjust the clutch. I read the how to and even have a manual. I can`t get the ball & Ramp back in right. I`ve been able to get it where there is a little pull after I take up the slack in the cable ,but , doesn`t seam to be working right. I`ve taken it a part 6 times now. Trying to get the ball & ramp to stay in place , but , with no luck , it seams to always return to the same place which is where it suppose to be when you pull the clutch. What am I doing wrong? Is there some easer way to do this? It`s the first time I`ve worked on a right side drive. It`s a 2005 Big Dog Chopper. If anyone has any advise I would appreciate it.
Thanks
 
francoblay1

francoblay1

The Spaniard
Wolfen,

After a few hours of battling with it... I think I´ve got it.... the issue (I think) it was that I was reassembling it with the cable in the "pulled position" FIRST PIC

Then I clicked.... it does not make sense... so started all over again... SECOND PIC

Going downstairs to put it together and I will be right back... Fingers crossed



[/QUOTE]
 
wolfen

wolfen

Member
Yes , I know that Francoblay1 , but , how did you get it to stay in that position when you put it back together?
 
francoblay1

francoblay1

The Spaniard
1. get the rod out. (I could not get it right till I took the F..r out) you will insert it later once you have resembled the unit.

2. release the whole tread on the cable (the adjustment part half way the cable going down the frame). Keep the Handle bars on the straight position, I´ve noticed, on my bike, it pulls a little bit when turning the handle bars to the right.

3. carefully assemble the unit, keep an eye on the cable´s half way adjuster and the lever so they don´t move. and tight it up.

4. Insert rod finger tight, then 1/4 turn out, and tight the nut.

5. Adjust the cable by the adjuster (the one on the down-tube frame)

&. E voila! :up:
 
W

woodbutcher

Mr. Old Fart member #145
Staff member
if you are wondering how the balls and ramps stay in place, the grease is thick and sticky enough to hold it all together. don't skimp on the grease.
 
wolfen

wolfen

Member
I got it work , but , still not happy with the adjustment. I have to tighten the thing beyond no lash to get it to work. It still lunges when I put in 1 st, gear. I don`t know what to do or where to start to look. The manual is of little use at all. I`m going to take a break and get back to it later .
 
Utopiapga

Utopiapga

Active Member
Wolfen if it is pulling when you put in firs gear with clutch pulled in you are REALLY close to having it just right. You need to stand bike upright and back out the adjuster rod just maybe another 1/4 turn and you should be spot on. The rod is still just a tiny bit to tight and will not let the clutch out fully.

One way I did it was to leave main cover off and put exhaust and everything back together, you should be able to still get a 11/16th wrench on the adjuster nut and also get a long allen wrench in between the pipes to turn the rod. If you have someone else that can help you, you can try this...............

Have wrench and allen wrench in hand then start bike and put it into gear. Now while holding clutch in with in gear make sure adjuster nut is loose, then start to turn rod SLOWLY until the bike try's to walk away with clutch pulled in then start to turn it back counter clockwise til it just stops pulling! Then with bike still up right lock that adjuster nut down and check to see if it is not pulling anymore. If good then take for a ride and see how it shifts and make sure there is no slippage! That is the best way I have found to get it JUST RIGHT.

If you still can't get it adjusted right then it is something other then just out of adjustment............clutch cable stretched, clutch going out, etc...........

Hopefully that will help you get it just right and that is all it is!

Good luck..........
 
alphadog

alphadog

Active Member
moedog said:
The one time I had issues getting my clutch adjusted right the clutch hub nut had gotten loose.
Click to expand...
X 2!!
Easy job to re righten. Every time I lose clutch cable pressure and comes back at higher speeds I know who the culprit is. Leave primary drained so red loctite can fully cure (24 hrs) Reverse threaded. 150 ft lbs of torque I believe. There is a how to I believe.
 
wolfen

wolfen

Member
I wish I had of left well enough alone. Now the bike is making all sorts of noises , like the heat shields are vibrating. But I checked and it`s not the heat shields. I`m going to have to take it a part again and start over. Make sure everything is OK.
 
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