gaddog
Member
Okay guys... here it is... solution found. Thought I might share the resolution of a mjor issue so someone else doesn't end up loosing 2 months of phenomenal riding weather. A couple of months ago I submitted a thread regarding some clutch issues and finally, 2 months later I have the bike back and fixed.
Brief History...
Was out riding my 2005 Pit Bull when I was hot rodding a bit from a stop light and shifted into 3rd or 4th (most likely 4th) and the clutch lever went slack. I was able to nurse the bike home and after reviewing the forum site, I found some threads about the dreaded loose clutch hub nut issue. Dug into the primary and sure enough it was loose. After re-securing it appropriately, I began riding it and didn't get more than a couple of blocks when it came loose again. This time I tried to re-secure it and upon trying to ride it, found I was having difficulty trying to get the clutch properly adjusted in 4th gear. I could get the clutch perfect in 1st-3rd but upon shifting into 4th the tranny wouldn't hook up and the clutch would slip like it was 20 years old. Replaced the clutch with a new soft pull. No Dice... same problem. After 5 times into the primary to make sure I had things right, I finally figured it wasn't my issue but something deeper in the tranny. Took it down to my local dealer (and by local I mean 120 miles away local) and said, "have at it." After 2 months, 2 clutches, tranny rebuild and 1100 bucks... (and three 220 mile roundtrips to pickup the bike when they said they had fixed it and hadn't) they found the problem. They also replaced 3 shift forks just to be sure (found some galling on them apparently).
Sollution...
Apparently there is some sort of retaining clip on the main input shaft that prevents movement of the 4th/6th gear cluster. The gears are Helical cut and without the clip, the pressure of acceleration causes the gears to separate slightly and allow the input shaft to push out enough to cause the clutch to disengage and allow slippage (and presumably allows the clutch hub nut to loosen). I probably could have found this but wasn't comfortable tearing into the tranny for a rebuild with no service manual for the tranny.
Spent the last two days riding the wheels off it.
Anyway... my two cents.
Brief History...
Was out riding my 2005 Pit Bull when I was hot rodding a bit from a stop light and shifted into 3rd or 4th (most likely 4th) and the clutch lever went slack. I was able to nurse the bike home and after reviewing the forum site, I found some threads about the dreaded loose clutch hub nut issue. Dug into the primary and sure enough it was loose. After re-securing it appropriately, I began riding it and didn't get more than a couple of blocks when it came loose again. This time I tried to re-secure it and upon trying to ride it, found I was having difficulty trying to get the clutch properly adjusted in 4th gear. I could get the clutch perfect in 1st-3rd but upon shifting into 4th the tranny wouldn't hook up and the clutch would slip like it was 20 years old. Replaced the clutch with a new soft pull. No Dice... same problem. After 5 times into the primary to make sure I had things right, I finally figured it wasn't my issue but something deeper in the tranny. Took it down to my local dealer (and by local I mean 120 miles away local) and said, "have at it." After 2 months, 2 clutches, tranny rebuild and 1100 bucks... (and three 220 mile roundtrips to pickup the bike when they said they had fixed it and hadn't) they found the problem. They also replaced 3 shift forks just to be sure (found some galling on them apparently).
Sollution...
Apparently there is some sort of retaining clip on the main input shaft that prevents movement of the 4th/6th gear cluster. The gears are Helical cut and without the clip, the pressure of acceleration causes the gears to separate slightly and allow the input shaft to push out enough to cause the clutch to disengage and allow slippage (and presumably allows the clutch hub nut to loosen). I probably could have found this but wasn't comfortable tearing into the tranny for a rebuild with no service manual for the tranny.
Spent the last two days riding the wheels off it.
Anyway... my two cents.
