What did I do wrong - Clutch
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6th Gear
Joined: Sep 2009
Posts: 12
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What did I do wrong - Clutch
I installed a 103ci big bore kit on my 09 Fatbob. I installed the heavy duty clutch diaphram spring that came with the kit. I also adjusted the clutch as per the manual. With the engine off, the bike will not roll with the clutch disengaged. (lever pulled). It rolls easily when in neutral. When in gear it will not roll freely whether you hold or release the clutch lever. It seems to make no difference. When in gear it is still turning the engine over with the lever pulled in. Any ideas on what I may have done wrong or how I can fix this.
Thanks
Thanks
Tourer
Joined: Oct 2008
Posts: 485
Likes: 0
From: Just outside of New Orleans, La.
I installed a 103ci big bore kit on my 09 Fatbob. I installed the heavy duty clutch diaphram spring that came with the kit. I also adjusted the clutch as per the manual. With the engine off, the bike will not roll with the clutch disengaged. (lever pulled). It rolls easily when in neutral. When in gear it will not roll freely whether you hold or release the clutch lever. It seems to make no difference. When in gear it is still turning the engine over with the lever pulled in. Any ideas on what I may have done wrong or how I can fix this.
Thanks
Thanks
Club Member
Joined: Dec 2007
Posts: 4,192
Likes: 168
From: Knoxville, Tn
Clutch Adjustment
When you are running the adjustment shaft in, ANY resistance you feel is where you stop and back it off 1/2 turn. Then lock it down with the jam nut.
Make sure you do this when the bike is stone cold otherwise it won't adjust correctly.
Tighten the cable up per the manual.
Make sure you do this when the bike is stone cold otherwise it won't adjust correctly.
Tighten the cable up per the manual.
Seasoned HDF Member
Joined: Nov 2010
Posts: 17,547
Likes: 7,153
From: Oxford, Nc
You or someone pulled the clutch lever during the spring install. You "flipped" the 3 ball ramp on the RIGHT side of the bike, where the cable goes in.
You'll have to pull that clutch actuation cover off and put the ramp back down to 6'OClock and reinstall the cover.
Then you can adjust the clutch on the left side, then the cable at the adjuster.
Common mistake....
You'll have to pull that clutch actuation cover off and put the ramp back down to 6'OClock and reinstall the cover.
Then you can adjust the clutch on the left side, then the cable at the adjuster.
Common mistake....
Ultimate HDF Member
Joined: Apr 2008
Posts: 5,384
Likes: 12
From: Out on Deranged
Shrewd man, peace out!
One thing I can ask you LINZ , you did the clutch adjustment with the cable quite loose and the bike cold right? But was the clutch cable maybe stuck out and caught by the aluminum tip of the outer cable? because I did that once. In that case you only have to loosen the cable and and start over making sure the end of the outer clutch cable is well seated in the clutch lever assy.
One thing I can ask you LINZ , you did the clutch adjustment with the cable quite loose and the bike cold right? But was the clutch cable maybe stuck out and caught by the aluminum tip of the outer cable? because I did that once. In that case you only have to loosen the cable and and start over making sure the end of the outer clutch cable is well seated in the clutch lever assy.
Thread Starter
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6th Gear
Joined: Sep 2009
Posts: 12
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Thanks for the replies. I readjusted it at least a half dozen times with no change. I did as Stiggy suggested and pulled the cover on the right side. Everything looked ok but I took it all apart and reassembled it anyway. I'm not sure what Stiggy meant by "flipped". Nothing looks like it can go anywhere it shouldn't be. Adjusted the clutch again after reassembling but still get the same result. With the engine off, rolls back and forth easy when in neutral. Put it in gear and it won't roll whether cluch lever is held in or not. I put it in 6th gear and can move it but very hard still. Removed plugs, held in clutch lever and rolled bike forward in 6th gear. Definately still turning over engine. I really don't know what to do now short of having to take it to the Dealer. I'm open to any other suggestions. Thanks to all for your time.
Linz
Linz
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Ultimate HDF Member
Joined: Apr 2010
Posts: 7,138
Likes: 26
From: Southern Oregon
When my bike sits over night I cant pull the clutch in and push the bike when its in gear. I always put it in neutral, pull the clutch in and start it... then put it in gear and go. My clutch has been adjusted by my indy and myself, its just something its always done
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Elite HDF Member
Joined: Apr 2007
Posts: 4,919
Likes: 23
From: Seattle, WA
The potential issue that Stiggy was alerting you to is if the tab on the inner ramp is not pointing up (or down as in the photo--which is upside down) ... it can sometimes be pointed toward the side where the cable comes into the cover when the '***** ramp over' ...
If it does this and the tab is oriented toward the cable, it will reduce the pull on the cable to nil ... and if the clutch is adjusted to engage, it will not allow the clutch lever to pull and disengage the clutch ...
This may or may not be your problem ... but, by ensuring the proper orientation of the tab on the inner ramp, you can eliminate that as a possible source of your problem ...
Good luck tracking down the problem and fixing it ...
R/
'Chop
Seasoned HDF Member
Joined: Nov 2010
Posts: 17,547
Likes: 7,153
From: Oxford, Nc
You or someone pulled the clutch lever during the spring install. You "flipped" the 3 ball ramp on the RIGHT side of the bike, where the cable goes in.
You'll have to pull that clutch actuation cover off and put the ramp back down to 6'OClock and reinstall the cover.
Then you can adjust the clutch on the left side, then the cable at the adjuster.
Common mistake....
You'll have to pull that clutch actuation cover off and put the ramp back down to 6'OClock and reinstall the cover.
Then you can adjust the clutch on the left side, then the cable at the adjuster.
Common mistake....
This puts the ramp where it needs to be when the cover is reinstalled with the 3 ***** in place.