Clutch lever suddenly lost pressure

Energy One
awg

awg

Guru
Jersey Big Mike said:
Well I disagree, if the cable is broken it is far more likely it is at the handlebar end -- every clutch cable that has broken on any bike I've ever had has broken here. And thats exactly waht it dounds like.
Is that clutch lever just flopping and pulling with doing nothing -- I'd take the handlebar end apart FIRST and check that cable (easiest fix)
Check botton end at ramp secondly
If neither of those then you'll need to pull the primary cover and open the clutch as it may be the clutch hub nut.
Click to expand...
I agree. Mine broke at the handle also.
 
Rintintin

Rintintin

Member
I tried for the simple approach with the adjustment process. No luck. I've looked at some videos about removing the exhaust (V&H Big Radius) and planning to go in this weekend pending receipt parts from HCM and Wild Steed Worx. Should be interesting.

By the way, when I first got the bike it ran poorly at low-mid throttle. I ordered a new set of jets specifically for the V&H exhaust and swapped them out. That really cleaned up the way it ran. :) (The bike had .0295 and .076 jets when I got it, and the V&H kit came with .031 and .076.) -- Just sharing some good news along with the clutch saga...

Dave
2006 Mastiff
 
Rintintin

Rintintin

Member
After studying all the great advice, videos and pictures from this forum, I dove into the problem this weekend. The clutch cable had broken inside the clutch actuator (not the lever). With the great support from many of you and quick shipment of parts from bigdogpartsking and wildsteedworx we are back on the road.

I prepped on Friday by applying penetration fluid to the exhaust nuts. Then on Saturday followed the guidance and removed the exhaust, opened the actuator and found the culprit (picture below of ferrule with broken end of cable). I then replaced the clutch cable, and clutch pushrod and inner actuator gasket. Greased up everything with high-temp grease, and put it back together. (I also polished up a few spots I couldn't reach prior to removing the exhaust.) After a couple of short rides it seems to be ok!

Thanks again for all the guidance and advice. Honestly, this forum and great parts support is why I chose a Big Dog vs the other brands out there as I am NOT a mechanic. You guys rock! A new picture of the pup at the (dog) park is attached.

Dave
2006 Mastiff
 

Attachments

HMAN

HMAN

I just like my Freedom
Rintintin said:
After studying all the great advice, videos and pictures from this forum, I dove into the problem this weekend. The clutch cable had broken inside the clutch actuator (not the lever). With the great support from many of you and quick shipment of parts from bigdogpartsking and wildsteedworx we are back on the road.

I prepped on Friday by applying penetration fluid to the exhaust nuts. Then on Saturday followed the guidance and removed the exhaust, opened the actuator and found the culprit (picture below of ferrule with broken end of cable). I then replaced the clutch cable, and clutch pushrod and inner actuator gasket. Greased up everything with high-temp grease, and put it back together. (I also polished up a few spots I couldn't reach prior to removing the exhaust.) After a couple of short rides it seems to be ok!

Thanks again for all the guidance and advice. Honestly, this forum and great parts support is why I chose a Big Dog vs the other brands out there as I am NOT a mechanic. You guys rock! A new picture of the pup at the (dog) park is attached.

Dave
2006 Mastiff
Click to expand...
Great job! You say you arent a mechanic but yet you turned your own wrench's. Guess that statement will have to change. As long as you have a bit of mechancal aptitude these guys will get ya thru most any issue. Glad you are back in the saddle with a great feeling of accomplisment! Ya done good!
 
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