Gents! And our ride or die Chicks! I recently went through 3000 miles on my Mutt only to realize that I could have had a much more enjoyable ride if my transmission was up to par. I recently went through the forum to find out why my clutch lever constant went loose and why I could rarely engage neutral at a dead stop, even sometimes getting the occasional gear slip. :bang: Come to find out most owners of BigDog motorcycles never check their Clutch Hub Nut to make sure it's nice and tight when servicing the Primary Fluid. After reading all of the money saving cures and How-To's I knew that it was time to check it all out. This past Sunday around 10am I propped my bike against the wall with some towels to make sure I didn't get anything scratched (obviously I don't have a lift, but I think most owners don't), and I proceeded to take the Primary cover off. Start by unscrewing the Drain Plug which is located on the right bottom side of the Primary Cover and drain completely, you may need to tilt the bike down that direction to make sure it all comes out, you should have about 32 ounces of fluid come out. Next, take off the Primary Cover but make sure to take it off really slow so that you can preserve the gasket and reuse when reattaching. When that cover is completely off proceed to take off the gear assembly by unscrewing the 4 main bolts, then take out the entire gear assembly, that will allow you to access the Clutch Hub Nut. When I got to this point I could literally turn the nut with my fingers and the light bulb above my head exploded, I couldn't believe it! 
Check out the attachment of how loose this nut was! So I went to the local auto part store, picked up some Brake Cleaner, some Red Loc-Tite, a Torque Wrench, and a socket for the nut (I believe 1 3/16 but take the bolt in to make sure). Take the bolt off, remember that it's Righty/Loosey, Lefty/Tighty, and spray plenty of Brake Cleaner in the nut and on the male bolt. Apply a little Loc-Tite on the theads of the male bolt and put the nut back on until snug. Next, tighten it up with the torque wrench to about 150 pounds, I stood on the bike and engaged the rear brake to make sure the bike didn't move while applying the 150 pounds of torque. After that is completed put in all back together. Make sure everything is nice and tight before putting the Primary cover back on. Make sure to synchronize the bolts up and down then left and right, from the middle working towards the sides, this is to make sure the gasket doesn't come apart inn the process. Next pull the middle cover of the Primary Cover and add a quart of Automatic Trans Fluid, (a good brand, I used Lucas). Tilt the bike down on its stand and let it sit for a bit to make sure you don't have any leaks.
I gotta tell ya, my bike has never shifted so smoothly and there is no more lag. If you haven't done this yet I suggest you try it. This saved my a quoted $500 from what I would have spent if I went to Stroker's here in Dallas. Well worth it. Let me know how it works for you!
Check out the attachment of how loose this nut was! So I went to the local auto part store, picked up some Brake Cleaner, some Red Loc-Tite, a Torque Wrench, and a socket for the nut (I believe 1 3/16 but take the bolt in to make sure). Take the bolt off, remember that it's Righty/Loosey, Lefty/Tighty, and spray plenty of Brake Cleaner in the nut and on the male bolt. Apply a little Loc-Tite on the theads of the male bolt and put the nut back on until snug. Next, tighten it up with the torque wrench to about 150 pounds, I stood on the bike and engaged the rear brake to make sure the bike didn't move while applying the 150 pounds of torque. After that is completed put in all back together. Make sure everything is nice and tight before putting the Primary cover back on. Make sure to synchronize the bolts up and down then left and right, from the middle working towards the sides, this is to make sure the gasket doesn't come apart inn the process. Next pull the middle cover of the Primary Cover and add a quart of Automatic Trans Fluid, (a good brand, I used Lucas). Tilt the bike down on its stand and let it sit for a bit to make sure you don't have any leaks.I gotta tell ya, my bike has never shifted so smoothly and there is no more lag. If you haven't done this yet I suggest you try it. This saved my a quoted $500 from what I would have spent if I went to Stroker's here in Dallas. Well worth it. Let me know how it works for you!
