Clutch said BYE

Energy One
BIG HOUSE

BIG HOUSE

DOG ONA DOG
Calendar Participant
Riding to the gentlemens club from Hooters last night I shift into 3rd gear and my clutch lever dosent return all the way. So I down shift same thing. Then it seemed like something in the trans was slipping(lugging). So I tried to slow down to pull over then no clutch. I limped home with no clutch:bang: Pulled apart the ball ramp assem every thing looks ok (including the shaft). So Gas and I reassembled but when we tried to adjust the clutch there was'nt enough adjustment so our first thought was the cable was stretched. We tried again loosened everything when we got back to the final adjustment it worked untill I pulled the lever then pop and the lever fell to the grip:bang: Any thoughts
 
BigDogBro1

BigDogBro1

Made in the USA
Hey House, Sorry to hear about your clutch problem. Glad you made it home okay.

Did the clutch cable lever hoop end break open or pull off the end of the pull cable at the lever?
 
slowrower

slowrower

2007 Mastiff
I wonder if the clutch actuator slipped, this happened to me when re-assembling the clutch the actuator ball ramp (I took it apart to grease it while adjusting the clutch) during re-assembly it was not fully extended when I put the pulley cover back. The net net of it was the clutch rod would not extend enough to disengage the clutch fully .. just a thought.

A few other possibilities:

The cable lock in the actuator has come off or is not seated properly
The cable is stretched
The clutch diaphragm spring is bad (see your manual for the spec)
The cable lock (on the hand grip) is gone or broken
Clutch Plates are worn out (must replace the entire clutch pak)

I sure there are more suggestions. Hope you find and fix it!
 
BigDogBro1

BigDogBro1

Made in the USA
Well, I'm not experienced with these clutches but if the clutch won't disengage then my guess is that the spring diaphram plate has broken or the throwout bearing blew out. I'm assuming the ball/ramp actuator assembly works fine.
 
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rwill20

rwill20

Well-Known Member
Damn Brother,sorry about your Dog hope U get it worked out,wish I could be of more help. Sorry Bro.
 
MN K9

MN K9

Well-Known Member
The cable was probably fraying....... then broke.

I thought a few guys on here have had troubles with their cables breaking.

Did you check that it's still intact after the lever went to the grip.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
Yeah House called me on this so in the middle of working a double I got out of work for a few hours to go help him..

"Gas Man's Mobile Bike Repair"


Getting it all tore apart



Adjusting the clutch rod


But then when it was still "popped" it went like this

freeplay adjustment


But lever still way out


The clutch rod was seated properly but it still was way loose. Plus when you pulled it... it didn't move. The cable pull was ROCK hard!

We played with it some more and finally got it to adjust correctly. He pulled it and we got a loud metal "pop" out of the tranny area. It happened really fast and couldn't tell exactly. Then the lever went back to like the pic above or maybe even closer to the grip. And ROCK hard again.

I was thinking broken carrier and the clutch rod is pushing out on the carrier, releasing the diaphram spring tension on the clutch rod, also giving us that "pop" noise and with the lever even adjusted out... the slack can't be taken up cause its simply pulling the ball ramp and pushing the clutch rod out. Hence why you can't take the freeplay out.

If its not the carrier I think something else is loose. Either way as I told House last night, we would need to get into the clutch and see what we find. He's apprehensive doing this on a warrentied bike. The end result will be 1 of 3 things. Either he buys the parts and we fix it, dog is down maybe only a week. OR We tear into it, find out what's wrong, yes it will cost money and parts, put it back together and let warrenty take care of it and pay. OR Just take it in, and let warrenty do everything.
 
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G

Gas Man

Cool isn't cheap
Calendar Participant
Slow... my guess to your questions

The cable lock in the actuator has come off or is not seated properly
Nope... it is seated and still has its farrell

The cable is stretched
OUr first initial guess, could be but that doesn't explain the rock hard cable that doesn't pull

The clutch diaphragm spring is bad (see your manual for the spec)
Could be and I hate diaphram springs for this... would prefer seperate coil springs. But would be a warrentied part.

The cable lock (on the hand grip) is gone or broken
Nope... good

Clutch Plates are worn out (must replace the entire clutch pak)
Don't think so... this was a instant pop and still wouldn't show these signs I don't believe.

BDB1... ball ramp is fine

MN... I don't think its the cable... it still seems to work and will move the ball ramp

The answer lies in the clutch pack. But to do that, we will have to pull the outer primary and dig in. Its not a complicated setup. Its just the warrenty issue.

I think House is looking for more ideas to help him decide to dig in or warrenty up.
 
05chop

05chop

Well-Known Member
If you remove the inspection cover on the primary.Take a flash lite shine it at the clutch plates.You might have to rotate the clutch a little. Have some one pull the clutch in.Now look and see if the basket moves or if the plates separate.This should give you something:job:
 
Mickeetwo

Mickeetwo

Guru
05chop said:
If you remove the inspection cover on the primary.Take a flash lite shine it at the clutch plates.You might have to rotate the clutch a little. Have some one pull the clutch in.Now look and see if the basket moves or if the plates separate.This should give you something:job:
Click to expand...
Smart idea Chop :2thumbs:
 
MN K9

MN K9

Well-Known Member
A dropped nut sounds painful!

Sounds like an easy fix. Can't hurt to try peek in there.
 
Chopper Dave

Chopper Dave

SIICK!!!
damn House...sorry to hear about your clutch....
Gas Man....you da man!!:up: :whoop: balling out the bike jack and tools for House.....cool shit!!:cheers:
House ...hope you get it taken care of....
 
BIG HOUSE

BIG HOUSE

DOG ONA DOG
Calendar Participant
Mickeetwo said:
Gas....Mine did the exact same thing. The nut on the clutch basket had come loose.
Click to expand...
You da man:2thumbs: After every dealership in Mi told me they could'nt even look at for a week I said piss on that and went in to see if the nut was loose and yuppers that was it. thanks guys
 
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