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Hello all, I'm sure there is an easy solution to this issue so be easy on me.
I replaced the belt on my 1986 FXWG 4-speed w/ factory kick and upon reassembly of clutch I went to put in the pushrod and the thing disappeared all the way into the main shaft. What the hell is going on? Everything ran and shifted fine, just a simple belt replacement. Now I can't adjust the clutch at all because the pushrod is WAY to far into the shaft. Help Please, summer is ending and rain is approaching.
Hey, nice bike !!!! Welcome from Connecticut !!! The push rod does go all the way in followed by a small rod with flat sides that touches the push rod at one end and the other end touches the adjuster with the lock nut and set screw, snap ring.
Did you forget that small rod ?
Last edited by glidein wide; Aug 31, 2016 at 06:34 PM.
Ha! I can say the same about your bike. Something about kicking over a bike [I]when you want to[I] that's pretty damn fun. Anyways, thanks for the reply. I don't remember seeing any little small rod, but I will scour the garage and see if I misplaced it somewhere. I also read over the repair manual and saw nothing about a 2nd rod. Also, I remember pulling out the pushrod and I couldn't have pulled it out if it was that deep inside the mainshaft. However my memory could be fuzzy since I was a few barley pops in at the time of disassembly. I'll keep you posted.
Looking at the parts diagram here, it looks like your '86 has the same clutch push rod assembly that came stock on my '90.
Should have four pieces:
- The little part holds the throwout bearing on one end and is cupped on the other (#6 on the diagram)
- The main pushrod, tapered at each end, about 10" long or so (#8)
- The other stubby piece to the pushrod, cupped on the end that touches the main pushrod, flat on the other (#7)
- The adjustment nut that screws into the clutch assembly (#11)
On my '90, there's no way to remove the main pushrod (#8) other than pulling the side cover off the transmission, removing #6, and pushing the rod out with a long screwdriver or something.
That's a long winded way of saying that I think glidein_wide is correct. Sounds like you pulled out part #7 and forgot to put it back in.
This is a pic of a telescopic magnet perfect for retrieving the push rods from inside the shaft. Like an old radio antenna.. goes from 6" to 21" very handy when dropping screw, nut,bolt or whatever in those tight spots that you'll never get your hand. Everyone should have this five dollar tool in their tray...couldn't tell you how many times I've needed it.
I've been trying (unsuccessfully) to post a diagram I'm working with. It's slightly different than the oem parts finder diagram 0maha posted. It doesn't show that stubby piece. It only shows the adjuster which has a cupped end that looks like it mates directly to the push rod. I also remember when I was dissambling the clutch I didn't need a magnet or tool to take out the pushrod. I simple grabbed it with my fingers and pulled it out. I'm thinking I put it in wrong? Or the tranny might not be the same 4-speed in the diagram? I don't know, it's not adding up.
Your diagram is not showing the clutch push rod at all. Look for another diagram. There should be one that shows the rod, maybe from the clutch cover (right side) side of the bike.
Is your primary all together ? Remove derby cover, snap ring and adjuster assembly, how far is the end of the rod from reaching the adjustment screw when it's pushed in all the way ?
Clutch pushrod problems
