Clutch help needed

[lee]

I posted a thread a while back explaining that when I shift from neutral to first, after starting the bike on a cold start, there is one hell of a clunk - an excessively clunky clunk, for lack of a better of phrase.

I adjusted the clutch today and after turning the pushrod all the way in (lightly), and then out half a turn, the clunk was gone but the clutch did not engage at all. I kept adjusting quarter of a turn at a time and I am probably back to where I started which I guess must be 1 1/2 to 2 turns out. The manual says half a turn I believe, so mine seems way too far out. As I say though, if its not as far out the clutch does not engage properly.

Any suggestions would be massively appreciated. I do have a new pushrod coming from Nelson as I read on here that some of the 05 ones were problematic but I'm not sure the pushrod is the cause of the problem.

Thanks for your help
Lee

 

[scubaman15]

This seems stupid to ask but have you adjusted the cable properly /do you have any freeplay in clutch handle? Also what type of oil are you running in the primary/when was it changed last.?

 

[lee]

HD primary oil and I changed it maybe 200 miles ago, Redline in the tranny and yes there is a touch of freeplay in the clutch lever

 

[05chop]

correct ilde?check the clutch pushrod could be hanging up.look inside primary inspection cover check chain then take a long pry bar and check for movement in clucth pack.I had a nut come loose on my basket my cable and clucth adjustment kept changing.check for correct oil level in primary.For shits and grins remove primary oil and look for metal shavings. 05chop

 

[Gas Man]

Well I was going to say that the clunk going into first usually is a result of the idle being too high. That is as long as its not lunging forward or some crazy shit.

 

[lee]

thanks for your replies gents - primary chain has been adjusted, idle seems fine (I actually upped it a little before I put the xxx on to stop the bike cutting out on this first gear change), changed primary oil recently and didn't notice excessive shavings - the clutch basket has not been looked at since I have owned the bike
GM - the surge forward you mention does happen - what could that mean because as soon as I am off and running everything seems ok - it is just that first shift from neutral to first

:bang: :bang: :bang:

 

[lee]

Thanks Sul - I'll take a look at the basket - the odd thing with this though is that as soon as I am off and running there are no clutch problems at all

 

[jwoolf]

Thanks Sul - I'll take a look at the basket - the odd thing with this though is that as soon as I am off and running there are no clutch problems at all

When you're in gear with the clutch engaged, does the bike pull or want to walk? That's the dead give away for the broken carrier. Of course, your symptoms could still warrant you to check the carrier. ( exp. since you have an 05 )

 

[lee]

When you're in gear with the clutch engaged, does the bike pull or want to walk? That's the dead give away for the broken carrier. Of course, your symptoms could still warrant you to check the carrier. ( exp. since you have an 05 )

no it doesn't pull at all with the clutch engaged - other than that initial shift into first (which can be horrendous) everything seems fine

 

[jwoolf]

no it doesn't pull at all with the clutch engaged - other than that initial shift into first (which can be horrendous) everything seems fine

Well, Sul's advice is always good here. I'd pull the primary cover and start inspecting everything.

Don't know how many miles you have on yours but, my carrier popped at 5k miles ( not too long after I got the bike ). I'd attempt to find out if your bike has the defective carrier in it. You may call customer service and give them your vin number and see if you do. If you're already going to be in the thing, you may want to replace it before it does break if you do happen to have the old one )

Even though my bike was out of warranty like yours is, big dog did supply the new carrier free of charge so, it's worth a call to them I'd think.

 

[lee]

thanks jwoolf I appreciate it - i have 3500 miles on it - I see Jakes also broke at 5k - looks like a new basket and carrier could be on the menu - great, I could really do with spending some more money! hows the wife's bike hunting going?

 

[jwoolf]

thanks jwoolf I appreciate it - i have 3500 miles on it - I see Jakes also broke at 5k - looks like a new basket and carrier could be on the menu - great, I could really do with spending some more money! hows the wife's bike hunting going?

Still stuck in the sporty mode. I can't get her to go for a dyna or softail.

Honestly, I'll probably try to split both worlds. I'll find her an old beater 1200 most likely for 3k - 4k then buy an old beater dyna or softail that needs some love and sell off the sporty next year.

I've got an everyday rider that I'm selling to a guy I work with and, we're both doing all of our bike buying with our bonuses this year so, I'll sell him my old one and, I'll buy two this year. LOL

We'll be up to three bikes in the garage. I'll have the Big Dog to show off on and we'll have two bikes we ride the shit out of. haha

 

[lee]

sounds good - keep us posted

 

[txchopperguy]

A high idle will make the clunk you refer to especially when the bike is cold on your first shift. I also dont think you should have any freeplay in your clutch handle, so a cable tweak may be in order to get things just right. I know the cable adjustment makes a big difference...so remember a little can go a long way. Just my .02
T

 

[lee]

thanks tx - but I thought you should have 1/16th freeplay?? maybe it is the idle - if it was something more sinister I guess I would have more issues than simply on the first shift

 

[txchopperguy]

If I am wrong on the slack in the clutch lever someone please correct me...I am no expert...I just thought the lever was not supposed to have any slack.
Lee, I have adj. my cable before and a 1/2 turn can make a big difference in the way the clutch acts when you have got it in the "sweet spot" so to speak. If nothing else you can put it back where it was if it does not help, and go forward from there. Hope this helps.
T

 

[chacha]

Manual calls for 1/16th free play when correctly adjusted.

 

[lee]

thanks for your help people I appreciate it

 

[05chop]

LEE IF you look at jakes photos of the broken hub carrier.Look at the rear of the broken carrier.There are six large holes to aid in cooling.See how the holes are symetrical? That is a early or old style. On the new bdm hubs or updated ones the holes are more triangular shaped.Hope this helps out. 05chop

 

[tacoloco]

If you tried all of the above most likely your clutch plates need replacement.
A noisy first gear is normal to a certain level but when it gets annoying you need to troubleshoot and get to the problem.