05 Mastiff can't get an adjustment on my clutch,
- Thread starter O Repo
- Start date
Possible is one steel plate that drags the whole pack. Have to remove the plates and stack the steels to see a gap of one steel dragging things up.
Remember, flat or cut side faces the pressure plate on assembly.
Remember, there is a specific stack of all plates for making the springs or wave plate to create spring tension or the wave plate shows a flat... sans, a loose output shaft nut being loose as knot explained.
Remember, flat or cut side faces the pressure plate on assembly.
Remember, there is a specific stack of all plates for making the springs or wave plate to create spring tension or the wave plate shows a flat... sans, a loose output shaft nut being loose as knot explained.
Ty Knothead I was thinking more like an arm on the fork maybe but no noise hope you're right Brother Thank you very much will let you know peace
Much appreciated Sven will heed all the knowledge you shared with me. Thanks for helping me.will let you know how it goes Peace Brother
Knothead i don't have a service manual and I'm not sure about where the nut you're talking about is located. First when I pulled primary cover it had groves in the cover from the pressure plate bolts. I got the clutch discs out, the friction plates had about the thickness of 2 pieces of notebook paper. The large nut in the center was half way off at the same time it was tight I couldn't get it to tighten any.. I wanted to check with you before I went any deeper. I have just a couple questions . From which side will I access the clutch hub nut i figure the right side not the primary side . I have the actuator cover off and the large 1 7/8 nut off. I didn't want to start pulling things off that didn't need to come off. If you can help me out I do appreciate it. If not I understand. Peace
knothead
Second Chance Customs
The nut your talking about being half way off is the one I'm talking about...that is the clutch hub nut is what hold the clutch basket on and it is left handed threads...you need to take it all apart and inspect it all...
Some one can point you to the manuals that is here on the forum
Some one can point you to the manuals that is here on the forum
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Thank you, Rotti, for being a keeper of the "Drop Box". Much appreciated.
Mikeinjersey
Well-Known Member
Thank to everyone that keeps the Drop Boxes available. The Forum works because of everybody!!!
Nothing obvious on inspection bearings everything appears to be seating right . Basket is in fine shape no grooves , metal discs are flat no warped or damaged disc. Friction disc are fine it never slipped it wouldn't dissengage completely..
is it possible the 4 pressure plate bolts worked there way loose? Without the hub nut loosening ? The hub nut appeared to be loose when I first looked at it there were 2-3;threads showing but it was tight with well over 80ft lbs. I'm going to reassemble make sure everything is torqued hopefully it was something unseen and is corrected if not we may just have a big dog bon fire I've put so much time and money into this bike only to find another problem just around the corner. Keeping my fingers crossed. Thank you for all your in put . Peace
is it possible the 4 pressure plate bolts worked there way loose? Without the hub nut loosening ? The hub nut appeared to be loose when I first looked at it there were 2-3;threads showing but it was tight with well over 80ft lbs. I'm going to reassemble make sure everything is torqued hopefully it was something unseen and is corrected if not we may just have a big dog bon fire I've put so much time and money into this bike only to find another problem just around the corner. Keeping my fingers crossed. Thank you for all your in put . Peace
Well if everything looked ok & was tightened when you opened it up your problem has to be in the cable and clutch pushrod adjustment right?
When I pulled it down the clutch hub nut was torqued but it had a couple threads exposed like it wasn't tight. And behind the nut was a washer that was 1/4 - 3 /16 thick I wasn't sure if that was correct washer. The clutch bolts were out far enough that the head of the bolts wore a groove in my primary cover over a quarter inch deep And I went n spoke with a local HD mechanic and when I ask him about the washer he said there shouldn't be a washer he pulled one out of his drawer that was a nut and sleeve all in one piece and he said he had never seen one with a washer .
So I clean and put it back together just
So I clean and put it back together just
And when I go to adjust the clutch I squeeze the lever, it squeezes 1/4 of the way and acts like the cable broke . I pull the cable off where it hooks to the tranny I pull the gismo with the 3 ball bearings it don't appear bad but I have no pressure on my clutch lever any ideas
Mikeinjersey
Well-Known Member
Look at these pages for the clutch and primary drive. This info is for a RSD.
Dropbox
Your explanations were a little hard for me to follow. I'm taking a guess here but it's possible the Ramps #50 and #52 were not in the correct position when you adjusted the cable. You referred to the ball and ramp system as " the Gismo" in your post. The Gismo is what gives the throw to the push rod. The cable pulls the ball and ramps which in turn pushes the pushrod # 44 into the throw-out bearing #12 which releases the clutch plates. The adjusting nut is # 10.
Give the adjustment another try first . If you still can't get enough motion to release the clutch pull the Gismo apart and inspect it and make sure you replace it giving yourself as much throw as possible. If you go back in be sure to remove and grease the pushrod along with the Ramp mechanism.
Attachments
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While you have the pushrod out, check the ends for wear. It is case hardened and eventually does break through the hardening. You can tell by the discoloration. Grease is your friend.
Started to mention the ball and ramp but figured that had already been checked. Sorry about that.
Started to mention the ball and ramp but figured that had already been checked. Sorry about that.
Where the cable end hooks into the gizmo, how far back is it? Meaning the inner cable end stretched out from its full throw. Might have it one ball or a notch forward. This would pull a shorter throw at the pushrod and would move the pressure plate out shorter and drag the plates.
Can you shoot photos of the gizmo's internals as shown in place? This way the eyes here can agree it's set correctly and agree as a group. Now shoot the tips of the pushrod photographed where the group will confer the rod is still useable.
Saying the clutch assembly scraped the outer cover or inspect cover, this says the big clutch outer floated out from the trans main shaft and this would be the center bolt being a left turn nut that tightens the clutch outer back against its output shaft.
If all shows good, the rod adjust nut on the pressure plate is screwed in till it stops, then pull lever to see if the pressure plate moves out at all. If not, has to be the gizmo one ratchet off and needs to be move back or move the end of the inner cable farther back. Then move the threaded adjust bolt off the pushrod by 1/4 turn out. Tighten the nut by holding the threaded screw from moving.
Go to the center of the cable and spread out the piggyback adjust housing to take up the gap of the inner cable. Run the adjust until you just ever so lost a gap at the lever to perch. Tighten the piggyback nut to adjust housing. Pull lever to see the pressure plate move out and spin the plate to see if it hangs up with a dragging warped steel plate.
Can you shoot photos of the gizmo's internals as shown in place? This way the eyes here can agree it's set correctly and agree as a group. Now shoot the tips of the pushrod photographed where the group will confer the rod is still useable.
Saying the clutch assembly scraped the outer cover or inspect cover, this says the big clutch outer floated out from the trans main shaft and this would be the center bolt being a left turn nut that tightens the clutch outer back against its output shaft.
If all shows good, the rod adjust nut on the pressure plate is screwed in till it stops, then pull lever to see if the pressure plate moves out at all. If not, has to be the gizmo one ratchet off and needs to be move back or move the end of the inner cable farther back. Then move the threaded adjust bolt off the pushrod by 1/4 turn out. Tighten the nut by holding the threaded screw from moving.
Go to the center of the cable and spread out the piggyback adjust housing to take up the gap of the inner cable. Run the adjust until you just ever so lost a gap at the lever to perch. Tighten the piggyback nut to adjust housing. Pull lever to see the pressure plate move out and spin the plate to see if it hangs up with a dragging warped steel plate.
BobbiFuller
New Member
Thank you so much, you made my day.