Clutch Hub Nut Was Loose, Tightened - Now No Clutch ?

[Th3InfamousI]

Hey Guys,

I'm having a hard time trying to figure out what I have done here.

I had a loose clutch hub nut and I re tightened down to 120/130ftlbs. Reassembled and readjusted the clutch twice and I the clutch lever feels good and I saw the clutch pack move out when the primary cover was off however once in gear rear tire will not spin AT ALL when Clutch Lever is pulled - Just like it's in gear no difference with the lever pulled vs not pulled in.

I'm trying to rack my brain to figure out what I did here. Considering the lever is tight and I saw the clutch pack move in and out with the cover off I can't imagine that the ball and ramp slipped out? As a note I didn't remove the clutch plates I had taken the 4 bolts off the clutch pack then realized I could just remove the snap ring without removing the clutch. So I put the 4 bolts back in tightened down to 20ft/lbs per spec. So I really couldn't have put it together wrong?

Bent clutch pushrod when putting in the throwout bearing?

 

[Th3InfamousI]

Here is a quick update:

Bike is on the lift when in gear and clutch engaged can't turn the tire manually by hand. When Bike is on and clutch is engaged the tire slows down but does not stop, if I rev it a bit and that re-engage the clutch tire stops and I can manually spin the tire with my hand. Turn bike off pull in clutch, no longer can I move tire by hand?

I guess what would cause me to be able to freely move the tire when clutch is engaged when bike is running vs not bike running?

WTF?

Just to clear the air this is how I adjusted the clutch:
1. Loosen Clutch Cable
2. Loosen Clutch Jam Nut
3. Finger tighten clutch push rod then backed off a 1/4 of a turn
4. Tighten Clutch Jam Nut
5. Tighten Clutch Cable


I'm going to try re-adjusting the clutch...again. I'll try backing off 1/8th of a turn this time maybe that will help.

 

[awg]

Hey Eric...when you took the clutch cover off to adjust the clutch does the cover unscrew to the left? I to need to adjust mine but cant get the cover to come off. And good luck! I'm sure someone will chime in for ya.

 

[BWG56]

Here's what happened to me once, make sure the retaining ring is seated correctly since you had the throw out bearing removed.

 

[KaptinAmerika]

How many miles are on the clutch pack

 

[Th3InfamousI]

Hey Eric...when you took the clutch cover off to adjust the clutch does the cover unscrew to the left? I to need to adjust mine but cant get the cover to come off. And good luck! I'm sure someone will chime in for ya.

Yes - I was trying to figure out how to get it off then I realized I had a small rubber strap wrench that worked like a charm! Although I did see in the manual there is supposed to be a gasket, which was not present.

Here is the Wrench I used! You can buy the set at Harbor Freight for about $5, I used the large one when I was taking my forks apart they come in handy.

 

[Th3InfamousI]

Here's what happened to me once, make sure the retaining ring is seated correctly since you had the throw out bearing removed.

Yea I triple checked that before I put the Primary on! But I don't know I might have to pull the cover off again and waste another Quart of fluid. But on another note why didn't BDM allow you to get into the primary without taking the whole cover off? Not sure why that back plate is just a decorative one

How many miles are on the clutch pack

Only about 5-6k miles. It worked 100% fine and clutch wasn't slipping before I took it apart so I don't think it's worn out just yet. I just had it apart to check the clutch hub nut because during a ride last season I had full slack and thankfully after a little riding and a couple power shifts it ended up coming right back. I finished the 1,000 mile ride with no issues.


Gonna try readjusting the clutch again now just got done eating dinner....see what happens.

 

[KaptinAmerika]

Yeah that's the one thing I don't like about the DSSC is no easy clutch pack access.
Made setting my auto clutch up a real pain in the ass.

Sounds like you just need to focus more on hitting that tight adjustment window the DSSC style BDs have.

 

[BWG56]

Sounds like you just need to focus more on hitting that tight adjustment window the DSSC style BDs have.

You got that right, I turned mine 5-6 times to get a good feel for it touching the throw out bearing and then backed off about 1/16 and I kept an eye on the location of the alan wrench so it didn't move when I tightened the rod nut. Especially using the soft pull with the 12 disc ckutch

 

[Th3InfamousI]

Update: -Readjusted Clutch only backed off about 1/8th of a turn this time. Lever is VERY Firm and feels very good.

Lowered the bike dropped it into 1st gear with the bike OFF and I struggled to push walk the bike forward or back and I could hear it was turning the engine.

I then started it up in Neutral dropped it into gear with the clutch and it did jump forward quite a bit, however after the initial jump forward it didn't continue to lurch forward. I was now able to hold in the clutch and easily walk the bike while in gear. What it should feel like even when bike is not running.

I turned the bike off with the clutch held in and while in gear and I was able to roll it forward and back easily still with the bike off. But then I put it in neutral and back into first gear and again unable to easily walk the bike forward and back with the clutch in.

Very odd that the clutch works great while the bike is running but not when the bike is off?

I doubt I would be able to start the bike with the clutch pulled in and in first gear. Not really wanting to try that.

 

[Th3InfamousI]

You got that right, I turned mine 5-6 times to get a good feel for it touching the throw out bearing and then backed off about 1/16 and I kept an eye on the location of the alan wrench so it didn't move when I tightened the rod nut. Especially using the soft pull with the 12 disc ckutch

I mean I think I've gotten this thing hit pretty damn good, and keeping the allen wrench right where it needs to be (I think) while tightening down the jam nut. But maybe it's gotta be just that spot on? When I pull the lever I can see the pushrod/jamnut moving in and out quite good.

I've adjusted my 04 multiple times and it's easy as pie. Granted its not DSSC but damn...

 

[Brew]

Did you let the bike warm up nice and good so the fluid thins out a bit?

 

[Th3InfamousI]

Did you let the bike warm up nice and good?

Before the clutch adjustment? Never done that before I've always adjusted cold with no issues on my 04.

And that would be a pain in the ass to get in that spot with hot pipes to adjust the pushrod and tighten down the nut. Gonna have to wear some BBQ gloves to do that one.

 

[Brew]

After the adjustments, take it for a spin around the block and bring it back and try to see if it'll move in gear with it off and the lever in. It'll loosen the clutch plates.

 

[BWG56]

I mean I think I've gotten this thing hit pretty damn good, and keeping the allen wrench right where it needs to be (I think) while tightening down the jam nut. But maybe it's gotta be just that spot on? When I pull the lever I can see the pushrod/jamnut moving in and out quite good.

I've adjusted my 04 multiple times and it's easy as pie. Granted its not DSSC but damn...

Your doing the same thing I did, and when I finally pulled the cover back off and I was inspecting the parts, is when I just happened to see the retaining ring end was out on the throw out bearing.
On another note you said you didn't pull the clutch pack out, the threads and nut really should be cleaned with brake cleaner to remove the oil residue, otherwise the loctite is worthless.

 

[Th3InfamousI]

Your doing the same thing I did, and when I finally pulled the cover back off and I was inspecting the parts, is when I just happened to see the retaining ring end was out on the throw out bearing.
On another note you said you didn't pull the clutch pack out, the threads and nut really should be cleaned with brake cleaner to remove the oil residue, otherwise the loctite is worthless.

I did clean it down with brake fluid...

Gonna take it for a spin see what happens.

 

[BWG56]

I did clean it down with brake fluid...

What the hell did you use brake fluid for? Should have used brake cleaner.

Sorry, couldn't help myself

 

[Th3InfamousI]

What the hell did you use brake fluid for? Should have used brake cleaner.

Sorry, couldn't help myself

Haha - Thats what I meant! Brake Cleaner..I had just posted on the other guys post about mixing DOT5 and had brake fluid on my mind.

Anyways took it for a spin seemed to unglue the clutch packs just slips really bad now in 2nd and 3rd - 1st seems pretty good. That 1/8th of a turn maybe is too much? I'll go back to a 1/4 and see how that rides.

I'm using the Lucas Oil Primary Fluid that Curtis stocks - I typically use Rev-Tech Non-Synt but I doubt that is causing the slip issue.

On the plus side the LED H4 bulb is pretty bright :lol:

 

[Brew]

I think you'll get it hammered out now!

 

[Th3InfamousI]

I'll give an update over the weekend. I adjusted to the 1/4 turn and was getting late and called it quits for the day.

I guess nothing was really wrong in the first place except the clutch pack was a bit stuck. I did have the primary off for a few weeks as I waited to get in a new nut. Maybe dried out the friction plates and needed to get them moving.