clutch cable disconnecting
 

I'm haveing an issue,my cluth cable,or the mechanism,not sure which happens first, is disconnecting inside thje primary case once in awhile. Everything seems good,can't see any reason. Anyone run into this before?

Sounds like an adjustment is in order. cable slack, cable replacement or clutch basket.

too much slack in the primary end of the cable and the small bulb on the end pops off

Hey Sasq, where you at? Canada is a big place :)

What year is your IronHead? L84 and newer or E85 and older? [Different clutches].

Need to follow adjustment process given in the factory manual exactly. Remember the actual clutch adjustment is done at the primary case behind the small cover; the control coil just does the free play adjustment.

Mick,I'm in Midland Ont, I have adjusted the cable according to factory specs,and the issue only happens once in awhile.like maybe once in 4 or 5 hundred miles. Oh,and it's a "76

When it disconnects do you then have to open the primary and put it back right? Or does it just feel disconnected and then fixes itself?

I expect it is the former. No, i have not run into this myself. Sounds like worn parts.

There is a part 34920-71 clutch cable coupling that hooks inside the case between the end of the cable and the ramp assembly. It is possible to install this incorrectly [upside down]. I wonder if this is what has happened.

Look carefully at any pics in the parts and service catalogs to see how it should be oriented.

Yes,I have to pull the primary off and put it back together.I was thinking the coupler or the ramp itself could be worn(where the coupler goes into the hole,possibly) I have had it apart quite a few times now,,but I go by the manual every time putting it back together.Think I will replace those two,and see. Thanks Mick