Help with clutch cable!

[carefreeinaz]

I had to buy a new clutch cable and it's one inch longer than the OEM. I got it from eBay and they told me that it was going to work just fine. Well I can't get my cable to pull the push rod far enough to disengage the clutch. I have followed all the instructions in the big dog manual and when I try putting it into first gear I better be holding on to that front brake because he just wants to take off like a K9 chasing a criminal. It seems like the ramp lever won't go back far enough and won't pull forward far enough. The push ride is only pushing about a quarter inch and it's supposed to go a half inch. I've done this dozens of times today and can't get it anybody have any input on this about the length of a clutch cable for a big dog motorcycle?

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[Mr. Wright]

Ok, this is a bit more information than the other post. When you adjusted the push rod, are you backing the rod off the throw out bearing, 1/8 turn?
Anymore than that, and it won't disengage. And if your clutch pack is wore you will have the same problem. Clutch pack needs to be a minimum of 1.970"

 

[Sven]

And if your clutch pack is wore you will have the same problem.

What? Pack is thinner. Screw has to come out farther. An 1/8 turn means more thread bite then 1/4 out at this point. Rod has a way farther throw to move plates off each other.

Worn plates shows the lever bits more near the perch. A well packed plate setup bits when it leave the grip.
Worn plates with an 1/8 out, bits near the perch. Look at how far your rod throw is now. Get it?

Shorten both cables to their lowest point of that center spreader in the middle of the cable... if applies.
Drop the barrel ends to their outer cables. touch both outer cable ends with each other that is opposite the drop. As those outer two bottom cables match each other, meaning, do the inner cables match equal length as well?

Kind of see the longer inner cable and the center spreader would pop out due to needing a shorter inner cable?

A way to tell if your ramp is being sent home is to shorten the outer cable with the spreader, hand on lever, screwdriver on pushrod screw and turn it in. Do you feel the lever head for the perch, then it stops and the screw won't turn anymore? You just send the ramp home. Can't go any farther. Back it out an 1/8th turn.

Go to the center spreader and run the outer cable out so the lever hits the perch. Take all the gap out of the lever. You now have more ramp at a higher point, meaning. With perch gap, you are taking up slack before the ramp starts its climb. Rather, a snug cable gap at the perch is a ramp starting sooner on the throw. Thus a shallow ramp lift if you go by the book and add perch gap.

 

[pauldeepsea]

I had to buy a new clutch cable and it's one inch longer than the OEM. I got it from eBay and they told me that it was going to work just fine. Well I can't get my cable to pull the push rod far enough to disengage the clutch. I have followed all the instructions in the big dog manual and when I try putting it into first gear I better be holding on to that front brake because he just wants to take off like a K9 chasing a criminal. It seems like the ramp lever won't go back far enough and won't pull forward far enough. The push ride is only pushing about a quarter inch and it's supposed to go a half inch. I've done this dozens of times today and can't get it anybody have any input on this about the length of a clutch cable for a big dog motorcycle?

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If it were me , I would return the cable . Get ahold of Barnett and they can get you the right clutch cable . Longer cable means it has allot more slack to take take up on which could be the reason your not getting proper alignment.

 

[Mikeinjersey]

I had to buy a new clutch cable and it's one inch longer than the OEM. I got it from eBay and they told me that it was going to work just fine. Well I can't get my cable to pull the push rod far enough to disengage the clutch. I have followed all the instructions in the big dog manual and when I try putting it into first gear I better be holding on to that front brake because he just wants to take off like a K9 chasing a criminal. It seems like the ramp lever won't go back far enough and won't pull forward far enough. The push ride is only pushing about a quarter inch and it's supposed to go a half inch. I've done this dozens of times today and can't get it anybody have any input on this about the length of a clutch cable for a big dog motorcycle?

Sent from my Pixel 3 using Tapatalk

The cable length should not be an issue if it fits and is adjusted correctly. Try this process for adjusting that Billy the Kid posted. It worked perfect for me. Jersey Big Mike also had some cautionary input worth noting.

Billy the Kid
Here is how I adjust mine, works every time shifts like a smooth Honda lol. Loosen cable adjustment all the way, run the clutch adjustment pushrod all the way in until it stops with light drag and keep it there. Then tighten cable adjustment up until you have no play at the lever and tighten up the cable adjustment, then go back down to the pushrod and back it out 1/4 turn. That should do it.
Jersey Big Mike
Be CAREFUL with getting the rod too tight then adjusting the clutch cable -- you can destroy the throwout bearing if your not careful -- ask me how I know!

 

[Sven]

No setup is incorrect. Only works one way. Look at all the combinations. What Mike said. When the engine parts expand, the rod gap narrows. Agreed?

How far out is the rod float? Say for argument sake is all of the argument. So .005" you push the rod back and forth, there is an oil gap to get in there so as not to burn out like Mike said. 1/8th turn out, float is now .00255555". Engine expansion is .001". So .001555" is the gap. That's some old CB450 Honda's [cold] valve lash at the cams... I said at the head, or the hottest part of the engine. We gapped?

Some neighbor's relative died. Left him a first year twinkie to be picked up. He's hooked on the ride. He says it's hard to get N. I walked him to the cable adjust and told him about the lever needed to be about here. I'm cutting the lawn days later, he shows up, finds N, gets off the idling bike, walks up the drive to open the garage. Walks back to the bike, drives it up, finds N, turns it off. I asked him how was the adjustment?

It's the throw don't you know... and don't get all mad I know my shit. Especially clutch setup on any bike brand... goes the generic. Flat/wave pressure plate...Single plate/multi plate, bring it on.

Signed,
NOLTT (no over load too tight)

 

[carefreeinaz]

Thanks Mikeinjersy, your input worked. After making all the adjustments and riding the bike around a block really helped and it's working fine now. I can let go of the clutch when you neutral and the bike does not travel anymore.

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[Mickmorris]

Thanks Mikeinjersy, your input worked. After making all the adjustments and riding the bike around a block really helped and it's working fine now. I can let go of the clutch when you neutral and the bike does not travel anymore.

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I hope you made a good video for YouTube