So this is actually not for a shovel, but my 84 FXST has a 4 speed in it, so I figured the shovel section was the place to check.

I just put my motor, trans and primary back onto the bike, and I went to try to adjust the clutch, and it doesn't seem to be happening correctly. When I turn the adjustment screw on the clutch basket, it has no effect on the free play of the clutch release arm on top - it just continues to swing back and forth. When the adjustment screw finally makes contact with the push rod there are only a small amount of threads left showing, and when I continue to tighten it it starts to engage the pressure plate and allows the clutch to spin, but there is still 100% free play on the release arm. What's up with that???

 

Wrong Pushrod?
Too many Clutch plates?
Too "fat" clutch [wrong stack height]

BTW
You did replace the throw out right??
Aligned it properly as well??

 

Did you take the tranny apart? Did it work before you took it apart?

Couple of thoughts...wrong pushrod, wrong adjusting screw, clutch pushrod not engaging clutch release finger (you will need to pull the right side cover to inspect) because retaining ring on pushrod assembly has come off.

 

I pulled the tranny and had the sprocket replaced, but did not open it up.

The clutch release arm was working before that.

When I re-installed everything it seemed pretty simple - just slid everything back into place - the clutch basket went right on to the tranny shaft. It didn't seem that there should be more to it than that. Did I miss something?

 

Think you need to pull the right side cover because the pushrod is not engaging the release finger.

 

Will give it a shot and see what's going on!

 

Is main shaft (tranny ) tapered ? Is the key for the clutch basket in the proper position on the main shaft ? Early 1984

 

second that - the key way slid up and out and its not now in its correct location

 

It's a late 84.The key on the main shaft appeared to be in the correct place - proper height and parallel to the tapered shaft. The clutch basket slipped right on and seemed to seat properly.

I did notice that the manual made a point to say to make sure that the key didn't move - mine was rigidly in place, so not sure how it might move?

 

Well... figured this one out!



I imagine those washers go on the end of the shaft with a new snap ring to hold them in place. I assume the order is with the regular washers sandwiching the roller washer?