Clutch Slippage or clunking for some reason in 3rd gear from the primary

[Nomad2day]

I have a 2007 Bulldog that I just put back together after the winter. In 3rd gear the primary chain clunks like it is locking up or perhaps the clutch is slipping and I hear the primary chain popping when it grabs. It will jump a time or two and then pull normal and then jump again. It does not keep just clunking all the time is what I am saying but will do it even if you are jusr riding steady. It does not do this in any other gear. I went to pass a car on a back road and blam or clunk, clunk in third. It will do it at low rpms or if you twist the throttle in third again all off sudden.

The clutch is a new stock clutch hub basket and clutch pack from BDM which they sent back with my transmission when they were looking at the tranny for this very issue this past winter. They never did tell me if they found anything and the dealer said the tag just said rebuilt transmission. Everything held good for about a week and they it started clunking after a 60 mile ride to Nashville on the way back.
The bike makes over 140 tq. at last check but I will not know for sure until I correct this and dyno it again.
Is 3rd gear and high torque a indicator of the stock clutch not up to the job causing this issue or do I need to look elsewhere.
How do I tell what spring rating is on the clutch diaphragm and where can I get the highest rated spring to help find my root cause here before I purchase a Bandit clutch not knowing for sure if this is my issue.

Backflash here of the last few weeks........
A couple of weeks ago I get the transmission in from BDM, powder coated wheels, new final drive belt and everything back together. Drive it to work a few times a week about 10 miles each way half interstate and half back roads and around town in the afternoons.. Thursday evening coming home I stop to get gas and the starter takes a shit and shears the jack shaft in half. Order one off of ebay. Put it in Thursday night and notice the final drive belt has loosened up a fair amount so I adjust the rear wheel to tighten the belt after installing the starter. Drive to work Friday and then to Nashville Saturday morning 60 miles all interstate. Going home the back roads I pass a car in third and the bike lunges and couple of times like it has slipped or as explained above. Bike has 300 miles are so on it from putting it on the road.
Thanks for any info,
Neil

 

[MARV]

there is a measurement to check the deflection of the spring plate. i'll see if i can locate.

your description sounds like a trans issue not a clutch issue.

if your looking to open er up maybe pull the motor sprocket and clutch and check runout on both shafts. ???

 

[Nomad2day]

Marv,
I found this thread by Dogvet on measuring the spring dome height.

For those of you who do your own service, anytime you have the primary cover off, it would be a good idea to check the diaphragm spring attitude.
Per the service manual, spring attitude should be between .010-.050". If the spring attitude exceeds that they recommend the measurement of the clutch plates.
All of this was new put in "clutch hub basket/ clutch" including the push rod when it all went back together.
I will call BDM as well and see what they said on the transmission in my bike records. Bob loves talking to me up there anyway, I hope....
I am going to go ahead and pull the primary cover and see what is happening in there.

http://www.bigdogbiker.com/forums/transmission-drive/4299-clutch-pressure-plate-wear.html

I let a local shop use my manual to work on a Big Dog they have in the shop and they open back up Tuesday so I will go by and pick it up or see what is says if anything on this.
Thanks for your time Marv.......:2thumbs:
Neil

 

[Gas Man]

 

[Nomad2day]

Thanks Chris for the info...

I pulled the primary cover off and nothing to write home about. Oil looks good with no crap in it and the chain adjustment is fine and nothing rubbing that I can see. The clutch is not binding and moves free. I went ahead and loosened the rear tire and took some tension off the final drive belt seeing how it was tightened up before this started again. Left the primary off tonight so I can go further tomorrow in there...
Thanks for the info and thoughts,
Neil

 

[Gas Man]

Could it be a shift fork? Sounds similar to what big House expierenced when he had a shift fork problem...

 

[Nomad2day]

Could it be a shift fork? Sounds similar to what big House experienced when he had a shift fork problem...

Chris,
I really do not know what is happening or what could cause this so I am trying to gather some other members experience on pointing at some causes.
We will make a calculated guess on which avenue to approach and cover all of them if I need too.......
I did in and find Big House threads and see what was happening with him.
I also sent Baker a email pretty much a copy and paste of my first post with a few more details to see what they say. I am going to call them "Baker" and BDM to find out what I can...
It is time to ride and not be dicking around with this thing...
Thanks,
Neil

 

[Gas Man]

I hear ya man. I know I don't want to wrench on a down bike. Wrenchin on some cool mods... ok. Wrenching to be able to ride = teh suck!

Did House's thread shed any light?

 

[Nomad2day]

Baker called me today and said they wanted the transmission in there shop asap to see what is happening and get everything rectified.
I called BDM and ask them to tell me what was done the last they had it for this and they returned the call late this afternoon but could not remember what was done according to the tech speaking to the customer service reps. I was also told no more tranny repairs are done in house but all go to Baker...I was asked to send clutch, transmission and all for inspection......Gave BDM the RA number to send everything back again but to Baker this time.
I really would like to know what has failed. I was told on the BDM side it could be a shift fork or main shaft possibly depending if I was getting on it. I was passing a car in third on a backroad....
I will update everyone when I know more. Now to pulling it back out...
I love this stuff. All my friends are ragging me but all the bugs are about worked out. It is still a Big Dog if it is in my garage or cruising down the road..Everyone has been cool working with me so far...
Neil
Update,
Transmission is back out and I will find some packaging tomorrow and build a crate...It is getting too easy to do this anymore. Too bad I am not Gasman's next door neighbor...Just think of the stuff we could get done....

Transmission is now shipped to Baker and will be delivered Thursday....
Neil

 

[Nomad2day]

I did send the transmission to Baker a week ago as Baker asked me too and called BDM to tell them what was going on and gave them the RA number from Baker. BDM said they would take care of it on there end.I talked to Baker yesterday on the status of it. I was trying to listen and write at the same time so I probably don't have this totally correct.
Problem was in the transmission. They ended up replacing 2nd gear, 3rd gear, 6th gear main shaft, 6th gear counter shaft. Had a bent fork and was burnt up as well. Swapped out the dogs from a 1 degree back cut to some with 4 degree back cut. Baker said they would take care of it under warranty and was trying to get square with BDM on there end but was waiting on them. They put in used gears and were not going to charge for those components but just the new bearings at $235.00. I don't have a problem with what they have done. BDM told me they no longer repair the transmissions in house but send them all to Baker now. Baker had another transmission in the shop at the same time for the exact same issue I was having????? Raise your eyebrow...Mine was just in over the winter for this issue at the pound and lasted 300 miles...On the other transmission, I wonder if it was someones bike on this forum, if so PM me and lets talk some.
Thanks,
Neil

 

[Nomad2day]

Makes me wanna cry when I walk out in the garage anymore...
Neil

 

[alhall88]

Any chance of it coming back an all Baker unit? Hope you get it back quick your losing riding time.

 

[Nomad2day]

Any chance of it coming back an all Baker unit? Hope you get it back quick your losing riding time.

Al,
That is a awesome suggestion,
I will call tomorrow and see what the deal is and ask them if they have not shipped it yet if I can upgrade it. I can't imagine what they might say about that...
Neil

 

[Nomad2day]

Transmission came in and I have finished installing it and took it out for a short spin due to all the downpour rain we are having. The weather broke enough to go out for a couple of hours. Everything is doing fine and nothing has fallen off in the road. It is Saturday morning now and the rain is still coming down big time. I used Spectro heavy duty platinum synthetic 6 speed fluid again in the transmission. It is shifting great and running good.
A big Kudos to Baker for a job well done and a big Thanks to BIG DOG for everything they do.....
Got a month to put some miles on it and then head to Wichita KS to thank them in person.
Neil

 

[Nomad2day]

I put a couple hundred miles on it this afternoon after the rain quit. Everything ran great and it was good to shoot up into Kentucky and get lost for a few hours........Riding the back roads until dark started on me and then hit the Kentucky parkway and interstate back. Only had to call the ole lady twice to google where I was at and tell me which way to go..

Neil

 

[Chopper Dave]

cool Neil! :up: glad to hear your back on the road! and your scoot is running good!

 

[lee]

like Dave said :2thumbs: