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Grab the clutch hub pull it outward and push it inward, does it move?
@Dan89FLSTC Yes, when I push/pull the clutch hub there is a definite movement...almost like its moving in and out of a groove like when you push an o ring in or out of a groove. I really am hoping this is the issue.
Tommy, everything worked fine before. I took the inner primary off to fix a long term leak and replace the seals in there. Once done I put everything back together and for sure did tighten the clutch hub nut a lot, i have a torque wrench but i may well have overtightened it, dont know. I test rode her and had a massive quick leak which i think was the shifter shaft tube for the mids that had been hit by the chain or something and lost my primary oil. I then reopened it all and "fixed" everything and when putting back together had the problem of the clutch basket too close to the inner primary and hitting the jack starter. I revisited all the starter and solenoid section and made sure all couplings were put in properly. The Clutch hub still sits too close to the inner primary so i can only assume its splines on the main shaft or the clutch hub.
Thanks Yankee Dog but yes all the couplings are correct - with very little effort I can push the clutch basket on so it pretty much hits the inner primary.
Sorry Dan, the clutch isnt on the main shaft. I dont see the point of fixing it on there until i can find a solution. So I'm pulling/pushing the clutch hub while holding the full clutch basket in my hand and thats when i felt the movement I describe above. I have tried pulling the main shaft earlier on and that was not moving.
My theory is that whatever should be stopping the clutch basket from hitting the inner primary is not working. So what I see is either:
1. The clutch hub splines have somehow "opened up" and are sliding too far up the main shaft
2. The splines at the end of the clutch hub are worn
3. The slight "shoulder" (at the end of the splines) on the main shaft is somehow worn and is not stopping the clutch hub?
4. Even thought the circlips are all in place in the clutch hub there may have been some movement somehow...clutching at straws here!
Basically I think this is where there must be a problem.
Oh ok. Thanks Dan Ill have a look for that washer in the morning .haven't seen anything that looks like that but will check now that I know what to look for.
Here's a thought...what of one or more of your trapdoor bearings are shot and there is play at the other end of things??? By that I mean, the clutch sits on the shaft juts fine but the shaft is moving back due to a hot or loose trapdoor bearing?
Hi @Dan89FLSTC I had a look inside the clutch hub bore and there is definitely no washer there but to be honest I dont think there is supposed to be, at least no on this bike. I've attached a photo of the parts page for the clutch and there's nothing there that looks like a washer? IVe also photographed both ends of the Clutch Hub so you can see there doesnt seem to be anything missing. I also tried the clutch on the main shaft and you can see the photo of the end and see that the clutch hub slides beyond the end of the splines. Just from looking at it you would think that what you say about a washer would be the solution and hold the clutch back from reaching the inner primary BUT there doesn't seem to be a washer?
Thanks Spanners....I checked the trap door end, opened her up and tried to move the main shaft but no movement.
Last edited by monchidog; Mar 18, 2025 at 05:04 AM.
Holy crap! I'm just looking back over photos to see if i can spot something and saw this.....Is this the washer you mean @Dan89FLSTC !!!
And that's what stops the nut from pushing the clutch basket back towards the inner primary when i tighten her down which was my fear? If thats the case then I suppose I can put the clutch basket on the shaft and push it back to were it sits comfortably in its correct distance from the inner primary and then i can tighten her up and with the tension from the inner primary chain the clutch will not "walk" back towards the inner primary?
Obviously if i push the clutch basket back by hand, it will go too far towards the inner primary so i figured there should be a block there of some sort but perhaps it is the tension of the chain?
I'm feeling particularly dumb right now if that is how it works and I've missed that all this time !
The washer is held in with a circlip.
It doesn’t show it on the parts because it’s not supposed to be removed.
New clutch hub time.
Replace the bearing, you can’t support the inner race when pressing out the clutch hub.
You need a new nut, looks rough, and I'm sure the end was booger from tightening it against the end of the splines, don't want it tearing up the new hub.
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