Adjusting the clutch on an '03

[aCASEortwo]

Hey guys,

I recently purchased an 03 Big Dog Chopper and have been trying to search for more information on adjusting the clutch. The cable is at the end of its adjustment and I was wondering if I pop the cover off can I adjust the clutch similar to the right hand drive setup in the "How to" section.

If it ends up being that I can't get enough adjustment out of it, is there any particular clutch kits you guys would recommend upgrading too? Or should I go back to getting an OEM replacement. I was looking at the Bandit Sportsman Clutch Kit.

Any suggestions or help would be great! And thank you in advance!

-Chris

 

[CCRainman]

The clutch is made by Primo and you don't adjust it like a RSD. You can take the cover off and loosen the lock nut on the clutch. Then you take an allen key and turn the center clockwise to adjust the ramp. You need to leave a little play in the lever. Once you get the lever to about 1/8 freeplay, tighten up the nut but make sur the allen key don't spin. That's the proper way of adjusting the 03's. If anyone else has any other suggestions chime in.

 

[Oscar Maldonado]

CC - Would that be the same on th 04'?

 

[CCRainman]

CC - Would that be the same on th 04'?

This is for the Harley type tranny. All the parts are from Primo. It's actually a Primo Brute 4 wet system if I'm not mistaken. When I took mine of and replaced it with the open belt drive which is also a Primo the cltch assembly was the same.

 

[aCASEortwo]

Thanks CC for the help,

I'm going to give it try today. Do you know what the torque spec is on the lock nut?

 

[CCRainman]

No I don't. I usually tighten it till it won't go anymore.

 

[aCASEortwo]

Do you guys have any suggestions where I can pick up a Bandit Sportsman Clutch kit? I was wondering if anyone on here sold them to help support another member. I adjusted the clutch and still seems like its at the end of its adjustment.

I found the Bandit kit on eBay for roughly $300, but I am a little hesitant about buying one off there.

Thanks!

 

[haze324]

there's a video on this site on how to do it, and it shows it very easy and simple . But I can't get it to load right now? Maybe they are having issues but try looking at it later. Its an easy process. Takes 5-10 minutes.

Pt 1: Adjusting Bike Clutch: DIY Motorcycle Maintenance & Repair Course | ExpertVillage Videos

 

[CCRainman]

Do you guys have any suggestions where I can pick up a Bandit Sportsman Clutch kit? I was wondering if anyone on here sold them to help support another member. I adjusted the clutch and still seems like its at the end of its adjustment.

I found the Bandit kit on eBay for roughly $300, but I am a little hesitant about buying one off there.

Thanks!

Call Vicky or WD

 

[CCRainman]

there's a video on this site on how to do it, and it shows it very easy and simple . But I can't get it to load right now? Maybe they are having issues but try looking at it later. Its an easy process. Takes 5-10 minutes.

Pt 1: Adjusting Bike Clutch: DIY Motorcycle Maintenance & Repair Course | ExpertVillage Videos

Nice find Haze, that's exactly how I try to explain it. Really simple.

 

[aCASEortwo]

Thanks again guys!

Just to recheck my steps: I pulled the cover off and adjusted the allen key with the lock nut, I turned it clockwise until it just started to get snug then backed it out a quarter turn. From there I adjust the cable to get the 1/8" free play in the lever.

One thing I have noticed is that when trying to snug up the cable to get the 1/8" amount of free play, the cable is nearly maxed out. Even with making sure the jamb nut on the cable is tight, I have had it happen twice now while ridding that the lever starts to dramatically increase in free play and sure enough the jamb nut on cable has loosen right up. Adjusted and tighten it up, and its good to go.

My thoughts were that if the clutch pack was worn there would be an increase in travel and with the cable nearing the end of its adjustment, I just would be unable to get it dialed in. Is it possible that I am just overlooking a worn cable? I do I just need to pony up and throw some red Loctite on the cable nut and bust out the pipe wrenches, lol. :loony:

 

[Gas Man]

You did do the allen key adjust with the downtube adjustment all the way in (the most freeplay aka loose loose)????

 

[aCASEortwo]

Yes, I loosened it up all the way on the downtube then made my adjustment on the clutch. More and more I am wondering if the clutch cable is stretched or worn. I am thinking Monday I might order up another cable and see if that does the trick. Its cheaper than ordering a clutch and is more money towards an HID kit. :up: