Primary/clutch help please

[nietoss]

I noticed my dog having the creeps at stop lights and a little rattle in the primary.. The bike only has 1500 miles on it.. Decided to take a look in the primary to see what was the problem.. When I drained the the primary noticed a bunch of shavings sticking to the plug.. When I took the primary cover off I noticed alot more shavings and 2 and a half hex bolts just sitting at the bottom of the primary.. I looked around the site and maybe I just missed the thread but can anyone tell me how to totally remove the clutch and chain so I can examine it further.. I have a service manual ordered but that might take a few days.. Any help would be great guys.. I love working on it myself and would like to keep it that way..

 

[outdoorsman26]

sounds like you need to pull your clutch and check to see if you carrier is rubbin on the inner primary, your clutch hub nut may be loose??? dont ride it til you do this!!!!!!!!!!!!!
then search " clutch hub nut" you will see how to do this!!! remember the hub nut is reverse threads!!!

 

[woodbutcher]

this is probably the best "how to" for your need. i know it is for changing to a belt drive but you should be able to get quality info from it. http://www.bigdogbiker.com/forums/how/16540-how-install-your-karata-open-belt-primary-obs.html

 

[BadBrad]

Any chance you could take of pic? Are the hex bolts broken off and just lying in the bottom of your primary? You should be able to see what they came out of. Most likely, the clutch, but a pic sure helps the rest of us see.

 

[nietoss]

Thanks guys.. I will take a pic as soon as I get the clutch off the hex bolts just fell out of the primary when I took off the cover.. They were pretty galled up..and I took out about a good handful of metal shavings

 

[BadBrad]

Well, it sure sounds like either the clutch hub nut came loose or the clutch basket broke. Keep us posted!

 

[nietoss]

here some pics. and sure isnt looking to good. i still need to remove the rest of the clutch and see whats going on.

 

[outdoorsman26]

wow!! so what bolts are broken??

 

[BadBrad]

Looks like the pivot plate bolts broke due to whole clutch sliding out. It ate up one of your friction plates too! With all your friction plates off, can't you tell if the clutch hub nut is loose or if your clutch basket is broken? One or the other allowed your whole clutch to move out and most of the shavings you're looking at are probably from the inside cover of the primary.

 

[nietoss]

Yea that's exactly what I found the clutch hub nut was tight... Im gonna look alittle more... Do u think I could just replace the plates.. I want to replace the whole clutch during the winter but already ordered exhaust and intake.. Clutch not really in the budget right now

 

[nietoss]

The 1 5/16 nut on the drive is standard thread right not left side thread?

 

[nietoss]

well unless i can think of some miracle to fix this it doesnt look good. any advice guys.

 

[Bobby Schulz]

Looks like the bolts came loose in the clutch carrier and then did some damage to the inner primary cover. I have a stock clutch and carrier setup you can have for free if you want it. Its the 12 plate system from a 05 but it does have the upgraded carrier from baker. If you need it PM me.

I would not worry about the inside primary cover...just take down any high spots that the clutch carrier would contact.

I also have a bandit clutch bruiser setup that I would sell you that comes with the billet carrier...I used it for 200 miles or so before I swapped over to a open primary belt drive. When I got the clutch adjusted right it worked great and I even have new bearings installed with the setup for who ever I sell it too... I will take $450.00 for it if you want to go that route.

 

[stlmikie]

Good for you Bobby! Stand up guy. I would jump on that nietoss. Get you back on the block.

 

[Brew]

Kudos Bobby...:2thumbs:

 

[aspen874]

that is a stand up offer, Bobby :2thumbs:

 

[BadBrad]

Looks like the bolts came loose in the clutch carrier and then did some damage to the inner primary cover. I have a stock clutch and carrier setup you can have for free if you want it. Its the 12 plate system from a 05 but it does have the upgraded carrier from baker. If you need it PM me.

I would not worry about the inside primary cover...just take down any high spots that the clutch carrier would contact.

I also have a bandit clutch bruiser setup that I would sell you that comes with the billet carrier...I used it for 200 miles or so before I swapped over to a open primary belt drive. When I got the clutch adjusted right it worked great and I even have new bearings installed with the setup for who ever I sell it too... I will take $450.00 for it if you want to go that route.

That's one hell of an offer. Before you decide what route to take, I would look a little closer as to the main reason this happened. It could be that a couple of clutch basket bolts came loose, but I've never heard of that happening. The spindle on the main shaft looks like it's ate up! I would think that you'll have to replace the main shaft before you decide on which clutch set up you want to go with. Is there any slack on the main shaft? Can you push it in and out? The bearings on the clutch basket don't appear to have failed but I just can't tell from the pics. If the bolts on the back of the clutch basket were not loose and the bearings on the clutch basket didn't fail, then something caused the clutch to move inwards and the friction with the inner primary cover caused the bolts to eventually break off. I'm not sure what might cause that but I'm sure there are some on here that might have an idea.

 

[nietoss]

badbrad the spindle does not have any play in it but the rod inside it does move in and out about 1/4 of an inch. also another question does the carrier mount straight onto the bigger sprocket. (not exactly sure Thats why im wondering if it mounts striaght on or if whomever worked on the bike before forgot a spacer or something. You can see the amount of play in the pictures and you can also see how far the bolts were backed off.

 

[BadBrad]

The rod inside it is the push rod and it should move. Pull your clutch handle in and you'll see it. From the last pic you posted, it damn sure looks like the bolts may have just backed out of the clutch basket that hold the outer hub to the sprocket. They should be locked in with red locktite. Is the spindle trashed where the bearings sit? If so, I would think you'll have to change it out. I'll let someone with a little more experience chime in on that. It may be that you can sand down the rough spots and go with another clutch. Really, all that looks bad is just the one friction plate and a couple of bolts. Is there damage to the sprockets? Oh, and yes, the carrier mounts straight to the sprocket.

 

[nietoss]

the spindle looks great. the only real damage is to that one friction disc like you said and to the back of the primary. there isnt really to much of a high spot on it. im thinking i can sand it down, and either replace the clutch or just get a friction disc and carrier.