Clutch Adjustment Problem

Energy One
Went on another ride today and rode about 110 miles and noticed there was alot of freeplay in the clutch lever and it was hard to shift. Almost no lever at all and would creep forward when stopped at redlight. Adjusted the clutch cable and all was good. Rode another 100 plus miles and now have the same problem. After cable adjustment all is good. Any ideas....
 

Mach_1

Active Member
If you look in the technicle forum under "how to" there is a great thread on how to adjust your clutch.
 
If you look in the technicle forum under "how to" there is a great thread on how to adjust your clutch.

Read the thread but wanted to make sure thats the problem before messing with it. If its something else would rather start there. Thought maybe someone else has had the exact trouble and could steer me in the right direction.
 

waternazzi

Active Member
Well i was riding one day and suddenly nothing?i pulled over and what i thought was a broken clutch cable turns out tobe a whole lot more.when i put it into gear (usually) the tranny should ingage.nothing it just rools like its in neutral in any gear?well like u guys say WTF! BD says they don't cover broken clutch cables either?? and yes its still under warranty.so what gives..
 

slowrower

2007 Mastiff
A couple of things to check, first try using the How-To link to make the adjustments if that doesn't work here is what to do/check. One last thing, if your clutch is also hard to disengage and finding neutral is all but impossible follow along.


1. Pull the belt cover off (3 hex screws)

2. Remove the the clutch adjusting locking nut with an 11/16" wrench
3. Remove the clutch push rod and inspect (should be nice and straight and come out easy.
4. Assuming your clutch is ok and keep in mind it can be shot with as little as 6,000 miles (just replaced one today). lets check the next thing
5. With your clutch cable still attached to the pulley cover check that when you squeeze the clutch the actuator turns properly. If not, take it apart and check for broken parts or a missing cable clip. If all is ok, re-grease and put everything back together.

6. Now its time to pull the primary cover to check the clutch and clutch pressure plate (this is was separates the clutch discs when the rod pushes against it).
7. Squeeze the clutch and verify how far it moves out (separating the discs) when squeezed.
8. If the pressure plate moves out to spec then your clutch pak needs to be replaced so be prepared to spend $200 for a new pak.


I took a bunch of photos during the disassembly and re-assembly process I will add to a how-to -- there are good ones there now!.
 
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Nomad2day

Longhair Redneck Geek
My clutch basket nut had spun free on mine giving me no clutch play at all. It would vibrate back and forth until the clutch basket backed off enough to start grinding on the primary cover. Pull your primary cover off and inspect the clutch basket as stated above. Should have red loctite on it but the BDM must of been getting off early the day he did mine. No loctite in the threads and BDM did not replace the primary cover saying it was cosmetic damage. The adjuster on the clutch cable also sheered off on the threads and would not replace the cable either, all on my penny. Bike is a 07 and only had a couple thousand miles when it happened.
 

waternazzi

Active Member
Well,thanks slowrower & nomad2day well to boot when i broke down and had to have it flat bedded BD said there not going to pay for it!once again WTF!this is bullshit!
 

Nomad2day

Longhair Redneck Geek
Nice job Slowrower.....
When I opened mine up it was obvious what had happened. Put it all back together after I checked everything out as well and had a BDM shop go back and check all the plates out and make sure all the metal was removed. Then they stuck the bill to me. Should of just done it all myself to start with.
Win some lose some, now I have learned to play their game.....
 
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Gas Man

Cool isn't cheap
Calendar Participant
Mine was doing the same thing the other day... still havent got into it yet... I'll be looking into the ball ramp, clutch rod, and pulling my plates...
 
Mine was doing the same thing the other day... still havent got into it yet... I'll be looking into the ball ramp, clutch rod, and pulling my plates...
Wish you would hurry up and check everything and let me know....I want to go riding :D :D
 

Gas Man

Cool isn't cheap
Calendar Participant
And I fuckin wish I wasn't working right now. This working days & night shift is really a fuckin drag!
 

BBChopper

Supports 2 Disabled Vets
Troop Supporter
A couple of things to check, first try using the How-To link to make the adjustments if that doesn't work here is what to do/check. One last thing, if your clutch is also hard to disengage and finding neutral is all but impossible follow along.


1. Pull the belt cover off (3 hex screws)

2. Remove the the clutch adjusting locking nut with an 11/16" wrench
3. Remove the clutch push rod and inspect (should be nice and straight and come out easy.
4. Assuming your clutch is ok and keep in mind it can be shot with as little as 6,000 miles (just replaced one today). lets check the next thing
5. With your clutch cable still attached to the pulley cover check that when you squeeze the clutch the actuator turns properly. If not, take it apart and check for broken parts or a missing cable clip. If all is ok, re-grease and put everything back together.

6. Now its time to pull the primary cover to check the clutch and clutch pressure plate (this is was separates the clutch discs when the rod pushes against it).
7. Squeeze the clutch and verify how far it moves out (separating the discs) when squeezed.
8. If the pressure plate moves out to spec then your clutch pak needs to be replaced so be prepared to spend $200 for a new pak.


I took a bunch of photos during the disassembly and re-assembly process I will add to a how-to -- there are good ones there now!.
Holy shit look out Gas!!!! Damn Show did you buy a brand new motor just for this post????:eek:
:roll: :roll: :roll:
Good post dude!! Bet ya used a torque wrench on that primary cover!!!!
 

Nomad2day

Longhair Redneck Geek
Na,
He is coming off the Michigan bike cleaning season.. About 6 months or so I hear..:lol: Plenty of time to shine it up inside out.
 
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