Clutch Pushrod adjustment
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6th Gear
Joined: Sep 2017
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From: De Pere
Clutch Pushrod adjustment
77 FXE.......Just replaced inner primary cover and rear chains and sprockets. Reassembling clutch and cannot get it to adjust correctly. Clutch is only about 1200 miles old. Everything seems to be assembled correctly, hub nut tightened correctly, springs adjusted to 1-1/32". Acts as though the pushrod is too short, can't get the clutch arm adjusted so it's 1/2" from the starter. When arm is 1/2" from starter, the adjuster screw is about 1-1/2 turns away from touching the end of the pushrod, so when I adjust the clutch cable there is so much free play that the clutch barely disengages. Am I having a brain fart here or did I miss putting something back in? It was adjusted correctly and worked perfectly before I took it apart.
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Joined: Oct 2005
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From: Santa Klaus County, Cali
On kickers the throwout bearing slides over the end of the clutch pushrod. On non kicker models it slides over the end and is held in place by a circlip. On either if it slips off the end of your clutch pushrod you will not be able to adjust your clutch properly.
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6th Gear
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From: De Pere
Thanks, I hope that's all it is. I will be checking that out tonight. I am guessing that if I pulled the pushrod out to far while working on this, that the bearing might have fallen off the end of the shaft?
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6th Gear
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From: De Pere
Washers, bearing, oil slinger all still on shaft with snap ring in place. Clutch lever is tight to shaft, release finger has only a slight amount of looseness on the shaft. Pushrod is 14" long and does not appear to be worn. Adjuster screw does not seam to have any abnormal wear on end where it contacts pushrod. Correct number of clutch discs all in position correctly, clutch hub tight. Only thing I see wrong is one of the welds on the gussets on the release plate is broken. Now what should I look for?
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From: Sheboygan, WI
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Seasoned HDF Member
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From: Santa Klaus County, Cali
Any chance the clutch hub is not fully on the shaft? Is it possible the key on the shaft has slipped (partially) behind the clutch hub so that the hub is not fully in place?
You just know it has to be something simple and basic.
You just know it has to be something simple and basic.
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6th Gear
Joined: Sep 2017
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From: De Pere
I will post pics tomorrow. I put in a Drag HD throwout bearing and pushrod set tonight. Was thinking that maybe a little wear on all the pieces would add up to my problem. Made no difference.
I have had the clutch off twice now to check things like the key placement. Looked in at the end of the key before tightening the nut and it looked like the key was where it should be.
This bike has been without the starter for the last 12 years, so I could have had this problem for a while and not known it because you can't adjust for that 1/2" starter clearance without a starter. That's why I put in a new inner primary, so I could reinstall the original starter. When you get to my age, you just don't feel lie kick starting 93" of engine anymore.
I have it all adjusted up to where I have good clutch feel on the hand lever, but the lever on the trans is about 1/8" away from the starter. I could run it like this, but what happens when I get some wear in the clutch, will I run out of adjustment when the lever hits the starter.
I have had the clutch off twice now to check things like the key placement. Looked in at the end of the key before tightening the nut and it looked like the key was where it should be.
This bike has been without the starter for the last 12 years, so I could have had this problem for a while and not known it because you can't adjust for that 1/2" starter clearance without a starter. That's why I put in a new inner primary, so I could reinstall the original starter. When you get to my age, you just don't feel lie kick starting 93" of engine anymore.
I have it all adjusted up to where I have good clutch feel on the hand lever, but the lever on the trans is about 1/8" away from the starter. I could run it like this, but what happens when I get some wear in the clutch, will I run out of adjustment when the lever hits the starter.
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Joined: Oct 2005
Posts: 7,499
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From: Santa Klaus County, Cali
One more thought based on your post above. Clutch pushrod length comes to mind...
41-64 (#37285-41) = 13"
65-69 (#37285-69) = 13-14"
70-75 (37285-70) = 13-7/8"
L75-E84 (37285-75) = 13-3/4"
How about pulling the pushrod and measuring the length?
41-64 (#37285-41) = 13"
65-69 (#37285-69) = 13-14"
70-75 (37285-70) = 13-7/8"
L75-E84 (37285-75) = 13-3/4"
How about pulling the pushrod and measuring the length?