Hello all, I spend most my time over in the Evo forum but today I need some help with my kicker and clutch and was sent here. I have a 86' fxwg with a 4 speed ratchet top. Troubles started when I changed the belt and upon reassembly I screwed up and can't figure out where.
I took it for a test ride and all was good until i pulled in the garage and the clutch lever had no resistance. I shut it down to assess and noticed the kicker wasn't engaging anything either. After fiddling with the bike I noticed if I start the bike with electric start the clutch returns to normal and kicker does too. If I try kicking it over I get three tries before the clutch goes soft and kicker stops engaging. I've adjusted the clutch over and over with no change. Retorqued the clutch hub nut and it's good. What is going on? Hopefully you kicker pros know what's up.

 

Pull off the kicker cover on the right side. If you put any pressure on the clutch rod when you disassembled the clutch basket you may find that your throw-out bearing is shot. If it did come apart make sure that you flush out the trans real good to be sure you get all the debris that may have fallen into the trans case. Also check to be sure that your clutch push rod hasn't been damaged on th e kicker side.

 

I had the kicker cover off already. Inspected the throw out bearing and it was fine, only missing the retaining clip which I replaced. The clutch holds adjustment until I kick it about three times then the kicker doesn't engage anything and clutch lever goes soft. Once I start it with the electric and shut it off, the clutch adjustment returns to normal and kicker turns the motor over... For 3 kicks then it's shitty again. It's Chinatown! I don't get it. What else should check? Completely disassemble the primary and clutch again and start over?

 

Throwout bearing still looking good

Nothing wrong here?

 

Under the derby cover I found that the clutch hub nut had backed out AGAIN! Threatlocked and torqued to 65 lbs., five pounds over the manual specs. I'm thinking threadlock and using an impact driver. How much is too much torque for this bastard? Dial up the torque wrench to 80? 90? Impact driver?

 

New nut time if the loctite isn't holding ......

 

the (( key way )) on the clutch hub is not staying seated or is not in place as it should be

start over as if nothing has happened = the clutch nut is counterclockwise to tighten and almost never do you see one come loose soo -- its not sitting in its correct spot - hub to main shaft and key way location