and again the clutch

[bigmax060472]

Good afternoon. I bought a 2007 Mastiff. The bike only had 4,000 miles. The clutch was very tight. However, the gears shifted perfectly. It had a 12-plate clutch. I read all the threads about clutches on this forum and decided to install a 9-plate clutch and an Easy PulL clutch. I ordered all the necessary parts and everything was installed successfully. Squeezing the clutch lever has become much easier. BUT! I can’t adjust the clutch. I adjusted the clutch in every way I found on this forum. But the following happens - after a complete adjustment, the gears shift perfectly, the free play of the clutch lever is 1/16. However, as soon as the bike warms up, I ride a maximum of 500-600 meters, the free play of the clutch lever increases very much. About half the lever travel. I adjust only the cable, everything is fine, I ride another 500-600 meters and the free play of the clutch lever is again half the travel. I'm doing a full adjustment again, but the same thing happens again. Does anyone have any ideas on what could be wrong? Thanks in advance!

 

[bigmax060472]

I just tried the following. After the ride, the clutch lever free play was about half of its full travel. Without touching the clutch cable, I unscrewed the cover that houses the clutch rod adjustment. The free play clutch rod was about 1/4 of a turn. So, there's no problem with the cable itself. The problem is somewhere in the clutch rod area.
Thanks!!

 

[bigmax060472]

I just tried the following. After the ride, the clutch lever free play was about half of its full travel. Without touching the clutch cable, I unscrewed the cover that houses the clutch rod adjustment. The free play clutch rod was about 1/4 of a turn. So, there's no problem with the cable itself. The problem is somewhere in the clutch rod area.
Thanks!!

Sorry - The free play clutch rod was about 3/4 of a turn

 

[bigmax060472]

and suddenly, unexpectedly, I heard a loud rotating noise in the area of the primary. There was no such noise before!

 

[HMAN]

Stop riding. Time to open the primary and see what is going on. Clutch rod should only be 1/4 turn. Hard to say what happened until you open the primary.

 

[bigmax060472]

I removed the clutch cover again. I took out the bearing. I didn't hear any additional noise. There was no play in the bearing. So, what's the problem?! And one more question: if I change the bearing, how do I remove the center part of the bearing where the pushrod fits (I've highlighted it with a red line in the photo)? Thanks!

 

[bigmax060472]

I removed the clutch cover again. I took out the bearing. I didn't hear any additional noise. There was no play in the bearing. So, what's the problem?! And one more question: if I change the bearing, how do I remove the center part of the bearing where the pushrod fits (I've highlighted it with a red line in the photo)? Thanks!

Sorry everyone. I figured out how to remove the center portion of the release bearing. This part comes as an assembly. But the question still remains: what's the problem? Thanks.

 

[bigmax060472]

The last thing I'd like to add is the strange reddish-brown stains on the clutch. The oil I drained was dark gray. I've attached a photo. I really hope that someone can help me! Thank you

 

[Chong]

Have you checked the clutch basket nut .. Mine was loose .. you could actually grab the clutch and move it in and out . I was chasing the same problem adjust, ride, loose clutch handle function , ie: became loose . The problem was the nut that clamps the clutch basket to trans shaft was loose, and after adjustment it would continue to loosen and loose clutch travel .. Pressure plate must be removed to gain access. When removing pressure plate lossen bolts uniformly, not each one all at once. To prevent pressure plate dammage. Tighten uniformly during reassembly also. 80ft lbs torque although people with 05+ often go higher which i was cautioned about. Nut is left hand thread on my 03. Red locktite i belive. This is a fairly common on 05+ bike.

Knothead diagnosed this for me and gave me the repair process.

 

[knothead]

Looks to me the clutch hub nut has backed off and now the transmission main shaft seal is leaking...looks to me the transmission fluild has never been changed and full.of moisture that causing it to look like rust.

 

[bigmax060472]

Thanks !is this the nut with the left hand thread? this nut loosen on its own? I didn't touch this nut when I changed the clutch discs. The motorcycle isn't near me right now. Unfortunately, I won't be able to check for another two days. I changed all the oils as soon as I bought the motorcycle.

 

[bigmax060472]

Knothead diagnosed this for me and gave me the repair process.

Thank you! Is there a description of this on the forum?