Frustrated, need help

[Firestream]

Need some help guys, have an 05 chopper with on-going clutch issues that dealer has been unable to solve. So I installed Bandit assembly along with their new carrier, bearing and new flanged hub from BDM. One of the updates the dealer performed was the shim behind the carrier and I left in place with Bandit install, checked alignment and clearance for new carrier and everything looked good. Started off with two shims in each spring cup as directed by Bandit and used their suggested oil (Spectro golden 80) and pre-soaked the clutch friction discs. Everything went together fine and all adjustments checked with a dial indicator. I set adjustment on clutch rod (well lubed) and adjusted clutch lever to spec. Time to test ride, clutch slipping... I decided to order the updated clutch rod and installed yesterday along with another shim. Went thought the adjustment procedure and, still slipping. Ended up with more shims to equal 404 pounds of pressure. Still slipping along with some vibration. Backed shims down to two each cup, tried several clutch rod positions (1/4 turn back, 1/2 turn back, 3/4 turn back and 1 full turn). still slipping... The good news is, no shavings in primary oil, so I know the carrier is not shifting around, but the slipping is really driving me nuts. Reading the manual, if clutch not adjusted correctly it will slip. Followed their procedure to the letter. Any suggestions would be appreciated...

 

[Gas Man]

IDK... I would call Bandit for sure. I believe John is the owner and he really knows his shit!

 

[Firestream]

I will call again monday. I may tear everything down again and check my tranny mainshaft for play and outer basket/sprocket for burrs or anything not allowing the clutch plates to move back and forth freely. But everything went together and checked out good during initial assembly, I even used blue machinst's dye on the back of the carrier in case I had a clearance problem. But I didn't check out movement on the mainshaft before installing carrier. Just one of those WTF moments...

 

[Gas Man]

What is the clutch lever freeplay doing during all this?

 

[Firestream]

Tried setting at 1/16 and then kept adjusting more and more slack to see if the clutch would grab and grind going into gear. Never got to that point, but when I had over 400 pounds of spring pressure I got a weird vibration at speed (70mph). I even used a dial indicator when I had the primary off between spring changes and everything seemed normal according to the bandit instructions. I thought I may have had things too tight, so I played with the settings, but keeps slipping. I have had the slipping problem with the stock set-up since day one and I only have 2700 miles of the bike. I ready to use it in a training fire!!

 

[BBChopper]

Use the Kiss system. loosen it till it creeps while in gear while stopped. If it still slipps you got clutch problems..

 

[05chop]

timing marks on the hub are they lined up?

 

[Firestream]

Do you mean the timing mark on the Bandit pressure plate to inner basket? Yes, you have to get the little dimple lined up so the pressure plate is seated.