CLUTCH OPINION PLEASE

[Dakota]

Guy's, I have encountered my first problem with my dog. Went for a ride this morning and in stopping for a light felt a give in my clutch lever when I down shifted. Had to apply the brakes to keep the bike stopped as clutch was not fully releasing. Got off to the side of the road to discover I now have about 5/8 to 3/4 free play in clutch lever that developed with one pull of the lever. Headed straight home bike shifted ok the only problems being stopped in gear with clutch dragging and some what easier pull on clutch lever. Bike is cooling off now and am looking for opinions on what the problem may be before I dive in. Cable ready to break, clutch hub nut, broken bearing carrier? Thanks for your thoughts.

 

[aspen874]

I have had similar issues, could be the ball and ramp, that was the problem on mine, also check clutch adjustment, then I would check clutch hub nut.

 

[BigDogBro1]

Don't ride it again untill you check this.

It's either the clutch basket nut has backed off, Clutch basket is failing or the clutch cable is pulling loose from the ferrule in the lever. More likely the nut.

Remove the primary cover and move the clutch pack left to right and see if the pack is loose on the shaft. Could have in and out movement as well. If it does then more than likely the nut has loosened up.

After removing the bolts that hold in the clutch pack you will be able to see the large nut. It's a left hand thread. It should be BLACK in color as well as the flat washer under it to be the NEW hardened type from BDM. Remove the nut and check the threads and the shaft and basket splines. Also check for any cracks in the clutch basket web arms.

Clean the threads on the shaft and nut with brake cleaner and apply a few drops of RED Locktite #2760 to the SHAFT and torque LH nut to 100ft/lbs. The factory torque was 80ft/lbs. Some claim to torque 125ft/lbs but I feel that's too much for the trans shaft.

Good Luck!

 

[Olde Man]

X2
I didn't know about the hardened washer. Do you think that this is the root cause of the loose clutch nut problem. Who sells the washers. I really hate doing it twice. I probably will do it when I address the mainshaft problem. Thanks for the info.

 

[Dakota]

Thanks for the advice will be getting into it this weekend.

 

[Dakota]

Got bike apart, got primary off, I loosened primary chain, clutch was rock solid could not get any movement out of it no matter how I pulled or jiggled it. Ball and ramp all good. The clutch cable not so good. Just two strands of cable left holding at the ferrule. Installed new cable I had on hand, greased up, adjusted, buttoned up, new primary fluid, test ride, all is good. Thanks again for the suggestions.

 

[gabe]

Yikes. that was close!

 

[Mickeetwo]

Thanks for the update.....Glad your up and running again :2thumbs:

 

[Brew]

Wow, gives true meaning to "hanging on by a thread" glad you found the issue and are back on the road...

 

[Rex Winters]

Luckier than me. When mine broke it failed completely. Had to limp 5 miles home with no clutch...