I'm stumped and hoping someone can help me. I have a 1982 fxr 5 speed shovelhead. I replaced clutch cable,clutch pushrod, shift finger, throw out bearing. And can not get clutch to disengage all the way. I have adjusted it to the book and tried ideas from posts all with the same outcome.

 

the cover with the arm that the cable connects to - the shaft and the door cover can be worn out and that causes the throw to change, not letting the arm travel far enough to dis in gauge

take it off and check after cleaning it and no oil on ether part looking for excessive looseness

converting it to the later ball ramp is another way to get it to work better

 

Thank you for the info. I will check that out and let you know how it goes. How do I find the upgraded ball and ramp kit

 

any BT 5 speed after 1989 you need the main door and the outer cover and all its workings the 3 *****, ball ramp and clip as well as the cable stuff

 

Thank you for the info. I checked out everything inside the door everything is tight except there is a very little side to side movement where the arm is bolted to the shaft. So it's either the arm causing the issue or at the handle bar lever. Where the cable goes into seems worn out.

 

Had the same problem on my 82 FXRS. My grip was to thick and my clutch lever wasn't pulling in enough to disengage. Changed grips and a thinner clutch lever, all is well.

 

Thank you for all your help. I will be getting a new lever and that should fix it.

 

If you upgrade the trap door and cover, make sure the cover is the one for FXR, with the cable going in through the lower inlet, otherwise it will not clear the mid controls
If you have forward controls, I think any will be fine
Another think you will need to do is make a bracket to support the starter, since the later trapdoor does not have the threaded hole for the oem bracket

 

 

I know this is an old thread, but did you resolve your issue because I'm having the same problem?