Clutch not releasing fully

[Purple Chopper]

Hi Guys, I have tried the search, but can not find what I am looking for so please point me in the right direction.

04 chopper clutch, will not fully release, it all adjusted to 1/2 a turn out at the clutch, and 1/16 free play in the lever.

I would like to know how to.

• Drain oil from primary
• Remove the primary
• Strip the clutch
• Re assemble the clutch
• Replace the primary
• Add the right oil

If any body has the manual, then a pdf of these pages would be great.

GREAT SITE KEEP UP THE GOOD WORK

 

[X-ray Doc]

Before you tear it all down, I would try the adjustment at 1/4 turn out and a little less cable slack. Several major clutch manufactures are recommending 1/4 turn out and almost no cable slack. That what it takes for mine to fully release. Hope it helps.

 

[BadBrad]

Try This

Hi Guys, I have tried the search, but can not find what I am looking for so please point me in the right direction.

04 chopper clutch, will not fully release, it all adjusted to 1/2 a turn out at the clutch, and 1/16 free play in the lever.

I would like to know how to.

• Drain oil from primary There is an allen head drain plug on the back bottom of the primary. Remove and let drain
• Remove the primary Remove all 14 bolts from the outer primary and remove. May be a little fluid left inside, so keep a pan/towel under it
• Strip the clutch Remove clutch pivot plate bolts, plate, clutch diaphram spring, throw out bearing, pressure plate and clutch hub nut. The clutch pack should come out now.
• Re assemble the clutch Install new clutch pack and reverse above
• Replace the primary Must replace/tighten bolts using the listed pattern. I'll see if I can copy that and send it to you. May need your addy for that. Too large a file for BDB
• Add the right oil I use a premium ATF, but do a search and use whatever you prefer.

GREAT SITE KEEP UP THE GOOD WORK

The PDF I have is for an '05. It's 75 MB. You can order a manual online.

If any body has the manual, then a pdf of these pages would be great.