Clutch Problems ....

Energy One
scubaman15

scubaman15

Well-Known Member
I think some of these problems were already discused ....but hears the problem I'm having The bike 07 chopper with 500+miles first service compleated by myself ..tranny has redline shock and primary HD primary oil .
After a short ride 30miles stopped at HD dealer hear stayed for 30mins left and problems started with clutch ...it seemed that the bike was very hard to shift at TIMES and clutch dragging at lights AT TIMES and other times it seemed ok but still not perfect netural hard to find etc. It seemed that after getting warmed up all of this started and it seemed that it was not the same each time ?? Could this be clutch push rod hanging/or basket coming loose because of heat? I love the bike but this is crazy for a bike with 500miles on it and the nearest dealer two hours plus away. I'm also pissed that I have to wrench on a new bike with 500miles on it. I will be pulling parts this afternoon to see if I can find the problem . I have long trips planned for the spring and this has made me rethink the whole thing. :rant:
 
BBChopper

BBChopper

Supports 2 Disabled Vets
Troop Supporter
scubaman15 said:
I think some of these problems were already discused ....but hears the problem I'm having The bike 07 chopper with 500+miles first service compleated by myself ..tranny has redline shock and primary HD primary oil .
After a short ride 30miles stopped at HD dealer hear stayed for 30mins left and problems started with clutch ...it seemed that the bike was very hard to shift at TIMES and clutch dragging at lights AT TIMES and other times it seemed ok but still not perfect netural hard to find etc. It seemed that after getting warmed up all of this started and it seemed that it was not the same each time ?? Could this be clutch push rod hanging/or basket coming loose because of heat? I love the bike but this is crazy for a bike with 500miles on it and the nearest dealer two hours plus away. I'm also pissed that I have to wrench on a new bike with 500miles on it. I will be pulling parts this afternoon to see if I can find the problem . I have long trips planned for the spring and this has made me rethink the whole thing. :rant:
Click to expand...
Probably just needs adjusting, they recommend at every service. Wont hurt to pull the cover and make sure everything is tight though!!!

http://www.bigdogbiker.com/forums/technical/2627-loose-nut.html


.
 
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jwoolf

jwoolf

Well-Known Member
Yeah, you're going to wrench on these bikes a bit but, after you get all the kinks out, they're pretty good.

Ask Ray, He's about to go on a 4000mi trip on his and regularly takes LONG trips on his. Others here do too.

Hang in there, it'll get better.
 
lee

lee

Well-Known Member
first off adjust the clutch - easy stuff first. Loosen the cable, spin the cover off and loosen the jam nut whilst holding the pushrod with a allen key - then screw the pushrod all the way in til you feel it seat, then back out a quarter turn then tighten the jam nut. Then tighten the cable so you got 1/16th to 1/8th free play at the clutch lever. Also check your heim joints at the ends of the shift linkage to check they are moving freely.
If you have to get the primary off to look at the clutch you could consider using Amsoil Extreme Gear Oil, rather than HD primary oil. A worthwhile upgrade in my opinion.
 
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scubaman15

scubaman15

Well-Known Member
I'm sorry if I was not clear but the clutch was adjusted and was perfect till it got hot ....I had this same problem before adjusting and it has returned after a long ride ... after adjusting . I will be checking clutch hub and push rod .. but this seems to be a recurring problem with BD
 
lee

lee

Well-Known Member
I jusr replaced my pushrod and it made a world of difference to my clutch - however, my problems were different to yours I'm afraid and the 2005 bikes were known to have a faulty pushrod - best of luck with it - let us know how you get on
 
dogvet

dogvet

Banned
scubaman15 said:
Thanks lee after reading all posts I'm leaning towards broken basket ?
Click to expand...
A broken basket would be an all the time problem and be noisey as well.

Check your primary chain tension at the tightest spot. Should be 3/8-5/8" when hot and 5/8-7/8" when cold. It gets tighter when hot. too tight and it will cause the clutch basket to deflect (causes drag).

Inspect your pushrod, specifically the end that rides in the throwout bearing. Should be nice and smooth. Inspect the length of the pushrod for signs of galling or rubbing (pay close attention to the end near the threads).

Try adjusting your pushrod as follows:

1. Loosen cable adjuster all the way.
2. with the jam nut loose, screw the pushrod in until it just bottoms.
3. back it out 1/4-1/2 turn.
4. While holding the pushrod in position with an allen wrench, tighten the jam nut.

5. adjust the cable till you have 1/16" of free play at the lever WHILE HOLDING THE CABLE END AGAINST THE CONTROL HOUSING.

This step is important because you can actually feel a false freeplay between the cable end and the housing instead of the cable itself. However, this typically leads to a slipping clutch.

If you still have problems, check for warped clutch plates or wave a dead chicken over your bike.
:flag:
 
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TSDAWG

TSDAWG

Yes, it's mine.
Calendar Participant
My 07 chopper did this at about 2000 miles. Popping the cover and tightening it helped, but the dealer that I go to said that that nut backs it's self off on these. I take mine to Thunder Cycles BD Dealer in Oklahoma City. The service manager can give you a quick disertation on his thoughts on it if you call. They are good mechanics there from what I"ve seen thus far. They reset mine and it's been fine since. I sure hope that's all that is wrong with yours! Don't freak out just yet. These are awesome bikes!
 
scubaman15

scubaman15

Well-Known Member
Thanks a lot ... I will be checking everything and resetting the push rod ..and hope this is all there is to it and not something broke already!! Some blue locktight on the jam nut?
 
G

Gas Man

Cool isn't cheap
Calendar Participant
Also put blue loctite on that adjuster cover... it will come off otherwise. trust me on this.

Also, on the freeplay adjustment... Alhall told me a old way of doing it vs eye ball. It should be able to pinch a dime between the lever and the control body.

 
scubaman15

scubaman15

Well-Known Member
Now that is a novel idea..gas I guess you put the dime in while adjusting free play at lever ...I'm going to try this after a complete clutch inspection . Let you all know ...rain and colder weather moving back in ,this weekend ?
 
LamboV12

LamboV12

Active Member
dogvet said:
A broken basket would be an all the time problem and be noisey as well.

Check your primary chain tension at the tightest spot. Should be 3/8-5/8" when hot and 5/8-7/8" when cold. It gets tighter when hot. too tight and it will cause the clutch basket to deflect (causes drag).

Inspect your pushrod, specifically the end that rides in the throwout bearing. Should be nice and smooth. Inspect the length of the pushrod for signs of galling or rubbing (pay close attention to the end near the threads).

Try adjusting your pushrod as follows:

1. Loosen cable adjuster all the way.
2. with the jam nut loose, screw the pushrod in until it just bottoms.
3. back it out 1/4-1/2 turn.
4. While holding the pushrod in position with an allen wrench, tighten the jam nut.

5. adjust the cable till you have 1/16" of free play at the lever WHILE HOLDING THE CABLE END AGAINST THE CONTROL HOUSING.

This step is important because you can actually feel a false freeplay between the cable end and the housing instead of the cable itself. However, this typically leads to a slipping clutch.

If you still have problems, check for warped clutch plates or wave a dead chicken over your bike.
:flag:
Click to expand...
DogVet - great write up...
Footnote - having exercised waving of the dead chicken on several occasions, I can attest it will only work if the chicken is from the northeast region of Peru and a virigin when killed. Been there - done it.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
Yeah I kinda held it there and tightened the freeplay up till it help the dime. Good to go.

But the credit for the idea is Alhall all the way. Some old school and super easy trick!
 
scubaman15

scubaman15

Well-Known Member
Update .

Removed Exhaust and Clutch today to inspect clutch found clutch rod with three deep grooves in it . Called BD and was informed about two old shops on the south side of Richmond that as of two weeks ago are now doing work on our dogs ...called one about trying to get a new clutch rod or having them do it but the thought of having the bike there for weeks did not sit well ....so I polished out the grooves with emmory cloth and reinstalled at first I think I had too much free play but after playing with "CABLE" a bit found a happy spot and gave it a pretty good test..about 15miles Time will tell if the rod will live a happy life ...also rejetted carb.... this was a worth it as it runs much better and plugs now have a good brown /tan color . I guess owning these bikes is more like a hobby with all the cleaning and wrenching . I have not bought a shop manual yet but if this keeps up ...I see one soon ..Thanks for all who gave advice.
 
dogvet

dogvet

Banned
05chop said:
Nice fix on the rod! Anyone know what it rubs on to get these marks? :job:
Click to expand...
since the tranny mainshaft rotates around the pushrod (it's held stationary by the clutch release), irregularities in the bore of the mainshaft rub against the pushrod. Give a good coat of anti sieze when reinstalling it.
 
05chop

05chop

Well-Known Member
Now i understand why they came out with a smaller diameter clutch rod.Keep metal out of the trany. 05chop
 
lee

lee

Well-Known Member
good work scubaman - if I were you I would get a new pushrod - $35 I think from Nelson and you obviously know how to fit it
 
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