Clutch lever suddenly lost pressure

[Rintintin]

I was enjoying a July 4th ride when as coming toward the end of a highway off ramp I pressed in the clutch lever and it just went dead. It lost all pressure and collapsed to the handlebar grip. I was able to pull to the side and slow enough to just basically kill the engine stopping while in gear. I looked at the clutch cable adjustment connection underneath the little black rubber cover and everything was tight. I loosened the nuts and tried to adjust to get tension to restore the clutch lever with no luck. It is not obvious that the clutch cable is broken or disconnected.
After an embarrassing ride home on a wrecker several hours later my new dog is back in the garage.

I did a lot of research on this site (great articles) and pre-ordered some parts (new clutch cable, ball ramp ferrule, push rod) in case these were needed. I also noticed some good threads about how to perform a clutch adjustment. I removed the side adjustment cover (the one beside the exhaust) and thought about trying the adjustment process but thought I would check here first...

Does anyone have any experience with the clutch lever just going flat all the sudden? This sounds like more than an adjustment. Any suggestions for where to start to diagnose?

Thanks

Dave
2006 Mastiff 4,700 miles

 

[jaggerz]

There has been a lot of issues with the clutch hub nut coming loose under the primary side. That may be your problem. If your cable is not broken that is probably what happened. There should be several posts on here on how to repair it. If the cable is broke it probably happened down at the ball and ramp connection. Been there. Jaggerz 2006 K-9

 

[Rintintin]

Thanks jaggerz. I'll pull that cover off and follow the steps for adjustment and be sure to tighten the nut well when finished??

 

[Mickmorris]

I was enjoying a July 4th ride when as coming toward the end of a highway off ramp I pressed in the clutch lever and it just went dead. It lost all pressure and collapsed to the handlebar grip. I was able to pull to the side and slow enough to just basically kill the engine stopping while in gear. I looked at the clutch cable adjustment connection underneath the little black rubber cover and everything was tight. I loosened the nuts and tried to adjust to get tension to restore the clutch lever with no luck. It is not obvious that the clutch cable is broken or disconnected.
After an embarrassing ride home on a wrecker several hours later my new dog is back in the garage.

I did a lot of research on this site (great articles) and pre-ordered some parts (new clutch cable, ball ramp ferrule, push rod) in case these were needed. I also noticed some good threads about how to perform a clutch adjustment. I removed the side adjustment cover (the one beside the exhaust) and thought about trying the adjustment process but thought I would check here first...

Does anyone have any experience with the clutch lever just going flat all the sudden? This sounds like more than an adjustment. Any suggestions for where to start to diagnose?

Thanks

Dave
2006 Mastiff 4,700 miles

So if you removed the the cover & the clutch adjustment nut is still in place. Most likely it broke @ the ball & ramp. This will likely require you to remove the pipes. I think Marky-Mark has a good Youtube video on this procedure on his K9.

 

[HMAN]

When mine did that on the way home from work, turned out to be a trashed throwout bearing. Dont overlook the small stuff. Baker has a beefer one available.

 

[jaggerz]

Not sure of the torque spec. Somewhere between 100 and 130 ft lbs. Also this is important that the clutch hub nut is left handed threads!!!! Clean the threads with brake clean and apply red loctite and torque. I always allow 24 hours for the loctite to cure before adding oil and road testing.

 

[jaggerz]

Hman Great idea I forgot about that. Jaggerz

 

[Mickmorris]

The clutch adjustment nut & the clutch hub nut are different things. The adjustment nut is right under the cover. 11/16 I believe & small hex head for the the adjustment on the pushrod. Doesn’t require a specific torque on the adjustment nut. The clutch hub nut is 150 # with red loctite.

 

[Rintintin]

Ooh. Great advice. I'm up for trying the nut and adjustment. HMAN, the throwout bearing is not something I'm familiar with. I'll school up on other threads about that. Is a throwout bearing something a garden variety mechanic can tackle?

I joined this thread and hoped to get to know everyone and chat before I started asking for help. I really appreciate your feedback on this unexpected turn of events

Dave
2006 Mastiff

 

[mleach72]

So if you removed the the cover & the clutch adjustment nut is still in place. Most likely it broke @ the ball & ramp. This will likely require you to remove the pipes. I think Marky-Mark has a good Youtube video on this procedure on his K9.

Yep, my original stock cable broke down at the ball & ramp.

 

[Rintintin]

The good news is I ordered a new cable, the bad news is "remove the pipes"

I'm keeping my fingers crossed it is the loose nut

Thanks

Dave
2006 Mastiff

 

[HMAN]

Ooh. Great advice. I'm up for trying the nut and adjustment. HMAN, the throwout bearing is not something I'm familiar with. I'll school up on other threads about that. Is a throwout bearing something a garden variety mechanic can tackle?

I joined this thread and hoped to get to know everyone and chat before I started asking for help. I really appreciate your feedback on this unexpected turn of events

Dave
2006 Mastiff

If you can tackle the other things, this is not a big deal. Its mostly turning wrench's. Got to pay attention to details. Taking pictures along the way can be very helpful too.

Heavy Duty Throwout Bearing Kit

People have been griping about the 37311-75 throwout bearing since it was introduced into Big Twins in 1975. Failures occur when the clutch cable is inadvertently adjusted with little to no free play. Performance clutches are even harder on that little bearing. The BAKER Heavy Duty Throwout...

bakerdrivetrain.com

 

[jaggerz]

Just to be clear, the loose clutch hub nut I spoke about is on the left side of the bike. Removal of the primary cover and clutch pack would have to happen to access it. jaggerz

 

[pknowles]

I was enjoying a July 4th ride when as coming toward the end of a highway off ramp I pressed in the clutch lever and it just went dead. It lost all pressure and collapsed to the handlebar grip. I was able to pull to the side and slow enough to just basically kill the engine stopping while in gear. I looked at the clutch cable adjustment connection underneath the little black rubber cover and everything was tight. I loosened the nuts and tried to adjust to get tension to restore the clutch lever with no luck. It is not obvious that the clutch cable is broken or disconnected.
After an embarrassing ride home on a wrecker several hours later my new dog is back in the garage.

I did a lot of research on this site (great articles) and pre-ordered some parts (new clutch cable, ball ramp ferrule, push rod) in case these were needed. I also noticed some good threads about how to perform a clutch adjustment. I removed the side adjustment cover (the one beside the exhaust) and thought about trying the adjustment process but thought I would check here first...

Does anyone have any experience with the clutch lever just going flat all the sudden? This sounds like more than an adjustment. Any suggestions for where to start to diagnose?

Thanks

Dave
2006 Mastiff 4,700 miles

If no issues before the lever went limp, i would look on the right side. Sounds like your cable let go. And most of the older cables brake at the ramp. I think the newer cables have a better end piece. Sounds like mine when it broke.

Just did a quick search and found the thread you need.
Search Blair R and clutch cable replacement on a 06 mastiff. Good luck.

 

[Rintintin]

If no issues before the lever went limp, i would look on the right side. Sounds like your cable let go. And most of the older cables brake at the ramp. I think the newer cables have a better end piece. Sounds like mine when it broke.

Just did a quick search and found the thread you need.
Search Blair R and clutch cable replacement on a 06 mastiff. Good luck.

Fingers crossed! Thanks pknowles21

 

[Jersey Big Mike]

There has been a lot of issues with the clutch hub nut coming loose under the primary side. That may be your problem. If your cable is not broken that is probably what happened. There should be several posts on here on how to repair it. If the cable is broke it probably happened down at the ball and ramp connection. Been there. Jaggerz 2006 K-9

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.

 

[Jersey Big Mike]

The good news is I ordered a new cable, the bad news is "remove the pipes"

I'm keeping my fingers crossed it is the loose nut

Thanks

Dave
2006 Mastiff

NO the last thing you want is loose nut as that frequently causes more damage, especially if it was loose and not noticed for a while.

 

[mleach72]

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.

Mike, it wasn't so much that cable actually broke. It was that the ferrule pulled off the end of the cable at the ball & ramp end. That's what happened to me, and I heard that it was a fairly common problem at one point. I think they make the cables better now.

 

[nvcollins]

A lot of advise from some knowledgeable people. Handle bar, clutch actuator (ball & ramp assembly), then primary. If broken cable you'll have to remove the exhaust and clutch actuator assembly. Let us know your progress.

Sent from my SM-A426U using Tapatalk

 

[Jersey Big Mike]

Mike, it wasn't so much that cable actually broke. It was that the ferrule pulled off the end of the cable at the ball & ramp end. That's what happened to me, and I heard that it was a fairly common problem at one point. I think they make the cables better now.

Well I've had cable break on my 02 bike (not a big dog) and on my K-9 and in each case it was the top end. Never heard of anyone having the other end go but really its only a little less probably when looking at the mechanics of the setup. Just never experienced it. Guess we'll have to wait to hear what it is.