02 Pitbull won’t move in gear

[mattylight]

I’ll try to make this as short as possible, I have a 2002 Big Dog Pitbull. 107 s&s motor. It was my fathers he passed away 2 years ago. It’s been sitting in my garage for about 10 years untouched. I got the bike running and it sounds great!!!! But it won’t move at all.

tire off the ground bike running it goes into every gear fine, tire in the ground bike running clutch all the way out it won’t move in any gear.

I pulled the primary cover off and inspected the clutch. It looks okay to me. I tried adjusting the clutch at the pushrod and at the cable and still nothing. Any suggestions would be greatly appreciated!!!!

Matt

 

[knothead]

I’ll try to make this as short as possible, I have a 2002 Big Dog Pitbull. 107 s&s motor. It was my fathers he passed away 2 years ago. It’s been sitting in my garage for about 10 years untouched. I got the bike running and it sounds great!!!! But it won’t move at all.

tire off the ground bike running it goes into every gear fine, tire in the ground bike running clutch all the way out it won’t move in any gear.

I pulled the primary cover off and inspected the clutch. It looks okay to me. I tried adjusting the clutch at the pushrod and at the cable and still nothing. Any suggestions would be greatly appreciated!!!!

Matt

So when u had the primary cover off did u operate the clutch lever and see if the pressure plate was moving in and out?

If all that is working correctly i wonder if the bolts on the clutch basket that bolts the primary gear are broken....

 

[mattylight]

Yes with primary off i operated the clutch lever and saw it moving in and out.

So when u had the primary cover off did u operate the clutch lever and see if the pressure plate was moving in and out?

If all that is working correctly i wonder if the bolts on the clutch basket that bolts the primary gear are broken....

 

[mattylight]

Absolutely nothing with the bike running trying to go into each gear, just revs. no noises or anything. But with bike off and tire off the ground i can see and feel it going into every gear

 

[knothead]

Yes with primary off i operated the clutch lever and saw it moving in and out.

U didnt see nothing laying in the primary cover when u took it off??

 

[mattylight]

U didnt see nothing laying in the primary cover when u took it off??

No, just old nasty primary fluid from years ago. I pulled the clutch friction discs out and it doesn't look smoked too me, although im not super familiar with working on motorcycles, just vehicles. Ill post a picture of my friction discs

 

[mattylight]

All of the discs are the same none look completely wiped out they are all similar

 

[Sven]

That is about the craziest wear pattern I've come across. What could rub that 1/2 side more than the other.... bent output shaft? Bent basket tangs on the clutch outer? Grooves at the clutch inner?

I wouldn't waste my time reassembling just to hand spin the pressure plate, but you can grab that center plate and spin with a few pliers on each side to grab with and spin it statically.

The pack is done. Buy as a set, meaning, you change chain/belt and sprockets as a set. Not half worn, half new. Especially holding that kind of torque from an engine like this.

 

[mattylight]

Bike off, in gear, and I am able to spin my clutch basket. Is this normal??????

 

[SKOGDOG]

That is a grand legacy bike—waaay to pretty to be sitting for years. I’m surprised no one has hotlined your ass for Dog abuse. Haha. That Pitbull needs to be on the road For many more years! And we definitely approve of guys who dig in and do it themselves, because that’s what most of us do!
Now down to business. Sven is right—strange wear pattern, and the entire clutch pack will need replaced (at minimum). Of course clutch should not spin when sitting in gear. I suppose the excessive wear could result in insufficient stack height—-that would account for that, and if the friction plate on the last photo is representative of the rest of them, I’m not surprised.
The wear indicates an alignment problem. Did you check the bearing carrier (#30 bottom left)? The OEM ones are made of cast aluminum and known to fracture. If it failed but didn’t crack all the spokes, it might create a misalignment that would produce a friction plate wear pattern like that. You have to go a bit deeper into the primary (remove the inner hub #20) to get a look at the bearing carrier tho.
If that turns out to be the issue and you are on a budget, you can probably find one here on the Forum, because a lot of guys have bought billet aftermarket from Baker, and have the old one laying around. I also think you can get one from the most popular replacement clutch, Bandit.
Or maybe an excessively worn transmission input shaft bearing would allow the whole clutch assembly to walk forward when engaging the clutch and produce that kind of wear, but you’d think the seal would leak transmission oil like crazy.....what do you guys think? That one would require pulling the transmission and
replacing bearings. Unless you are a machinist, you’ll need to contact Andrew Barnes or a similarly skilled wrench.
in any event, find a post from Mr. Wright, and look at his signature block. You’ll find a hot link to the repair manuals. Go buy in. lb. and ft. lb. torque wrenches and follow manual directions—these bikes aisn’t your Dad’s ‘82 Shovelhead....
And do get back with us to tell us how it went...or to ask more Q’s.

 

[mattylight]

My 02 clutch assembly does not look exactly as pictured, although I understand what you are trying to tell me. I will have to disassemble further and report back to you guys. I appreciate everything so far and yes, this bike is way to pretty to be sitting. I should have put fire under my a** years ago, but at least I am on it now. The bike is priceless to me and I’m willing to fix whatever need be.

 

[mattylight]

This is a look into my primary, slightly different from your picture it looks like

 

[awg]

Your dad would of been proud. Keep up the good work.

 

[Mr. Wright]

Here is a link to the manuals. This has me baffled too.
I think the pictures are giving an optical illusion on the wear pattern. Skogdog posted the wrong year clutch assembly.
What I want you to do is raise the back tire off the ground, put it in 6th gear, and see if you can spin the tire. Then reassemble the clutch and do the same thing. Let us know what happens.

Dropbox

www.dropbox.com

 

[mattylight]

I will report back after work, although the bike is a 5 speed I’m fairly certain

 

[Mr. Wright]

You are correct.

 

[SKOGDOG]

My bad—and I know better.

 

[Mr. Wright]

My bad—and I know better.

Not holding it against you. Just letting the new guy know.

 

[Jersey Big Mike]

When you put it up and run the engine, when you shift do the wheels move than -- you imply they do I just want to verify.
MY BDM that I just sold sat for quite a while and the brake pistons locked on me and the wheels wouldn't turn. Pulled off the brakes so AI could roll it out of the shed.

 

[mattylight]

Damn this bike is beautiful, I’m going to put the rear wheel in the air In the air now

Here is a link to the manuals. This has me baffled too.
I think the pictures are giving an optical illusion on the wear pattern. Skogdog posted the wrong year clutch assembly.
What I want you to do is raise the back tire off the ground, put it in 6th gear, and see if you can spin the tire. Then reassemble the clutch and do the same thing. Let us know what happens.

Dropbox

www.dropbox.com

The brake caliper is not sticking, with the bike running tire in the air in gear the wheel was moving. It doesn’t do anything on the ground

When you put it up and run the engine, when you shift do the wheels move than -- you imply they do I just want to verify.
MY BDM that I just sold sat for quite a while and the brake pistons locked on me and the wheels wouldn't turn. Pulled off the brakes so AI could roll it out of the shed.