NEED HELP!!!!!CLUTCH???

Energy One
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rulirini

Member
I have a 2008 mutt with 2,500 miles. about a month or two ago I noticed a noise from the primary when in between gears...serviced the primary with full synthetic Mobil oil 20-50w. noise continued but since it was minor it disregarded (bad on my part)...yesterday while on a bike run I had to adjust the clutch cable in order to be able to shift... after about 40 miles on the highway there was excessive play on the clutch lever again, I had to adjusted again to be able To get home.

opened the primary to have a look and I noticed the 4 bolts holding the clutch assembly were slightly rubbing on the primary cover. anybody have any idea what caused the bolts to rub against the cover. I was thinking I had a clutch problem but know I don't know.
 
Brew

Brew

Troop Supporter
Yeah your clutch hub nut most likely loosened up. You need to remove the nut and clean the threads on the main shaft and the nut and goop it with red loc-tite. Dont forget the hub nut is reversed threads, so righty is loosy and left is tighty... Also I would suggest you not run full synthetic oil in your primary. It can cause slippage issues...
 
Brew

Brew

Troop Supporter
I would think the clutch plates are fine. When the hub nut loosens the whole clutch assembly moves out so, no damage to the clutch. Just your primary cover gets a little grooved.
 
Splitlog

Splitlog

Well-Known Member
Clutch is fine at that mileage. Just loose hub nut. Lock tight 150 lbs torque. And no synthetic in your primary.
 
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rulirini

Member
Clutch hub nut was loose as expected. cleaned main shaft, added plenty of loc-tite, and torqued clutch hub nut to 150 lbs. gears are shifting fine, but there is still a weird noise coming from primary when in neutral.???????Im thinking It might be the chain????..any ideas...
 
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bigdogtech01

Well-Known Member
rulirini said:
Clutch hub nut was loose as expected. cleaned main shaft, added plenty of loc-tite, and torqued clutch hub nut to 150 lbs. gears are shifting fine, but there is still a weird noise coming from primary when in neutral.???????Im thinking It might be the chain????..any ideas...
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Chain should be 5/8" -7/8" free play cold. Did you check to make sure front sprocket nut was tight as well? They can come loose and if left loose, the charging rotor can move back and forth on the splines of the crank and eventually wear the splines out on the rotor.
 
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rulirini

Member
Ill re-adjust the chain just to make sure. front sprocket was fine. It almost sounds like the noise is coming from the transmission gears????
 
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bigdogtech01

Well-Known Member
Do you know for a fact the bike only has 2500 miles on it? or did you buy it used? Reason being, the transmission bearings shouldn't be worn with that many miles (but anythings possible)...but you might have a loose or broken off counter shaft bolt. I just had a Mastiff in my shop that had one broke off so I had to have the bolt burnt out by a machine shop. The customer had been having problems with the bike since the day he purchased it brand new...5000 miles later, it was stuck in 4th gear because of counter shaft assembly walking.
 
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rulirini

Member
I bought the bike brand new, original miles 2500. the bike sat at the local dealership for years. I had no shifting problems or clutch problems until the clutch hub nut issue. fix it know I have a rattling noise at idle and it gets louder as the RPM are higher. I just saw a thread for a loose compensator nut, I'm going to look into and hopefully that helps. Thanks.

FYI I noticed the rattling noise before the hub clutch nut issue. fixed the hub nut issue, the noise is still there.
 
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bigdogtech01

Well-Known Member
rulirini said:
I bought the bike brand new, original miles 2500. the bike sat at the local dealership for years. I had no shifting problems or clutch problems until the clutch hub nut issue. fix it know I have a rattling noise at idle and it gets louder as the RPM are higher. I just saw a thread for a loose compensator nut, I'm going to look into and hopefully that helps. Thanks.

FYI I noticed the rattling noise before the hub clutch nut issue. fixed the hub nut issue, the noise is still there.
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You will have to pinpoint the noise, at least try to...it might be something loose on bike. Take some wrenches and check to make sure some of the bolts are tight, such as...Upper and lower motor mount bolts, shifter linkage, plastic side covers, exhaust system...
If it's coming from the transmission, you might have to dig into it.
How long has it been since you changed your motor oil? What type? Did you clean the tappet screen? Sometimes you will get noisy lifters/tappets if the oil needs to be changed or the tappet screen is dirty.
 
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rulirini

Member
I'm almost certain the noise is coming from the primary area. changed about 400 miles/2 months ago...Mobil v-twin motorcycle oil 20/50w.
 
Knuckles

Knuckles

Active Member
I'm having the same problem. almost a grinding our whine noise. louder on start up and bike having problems turning over. let me know what else you try and I'll check the same items.
 
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rulirini

Member
pin-pointed noise to the transmission pulley side. removed transmission pulley cover and nut that holds transmission pulley is loose. will tighten the nut and hopefully the problem is fixed.
 
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