Hi all,

2002 Heritage Classic, EFI. Had the clutch checked so I know it's not that; here's the symptoms -

- Usually in lower gear, 1-3, when I roll on the throttle it sometimes hesitates or the RPMs go up but no increase in speed until something catches/engages and it surges forward. It happens from a stop or when changing gear, maybe all below 40 mph
- this only seems to happen when it's warmed up, after at least 10 minutes of riding
- The longer the ride the more it seems to affect idle, when it was hot the other day it felt like I had to keep the throttle revved at a red light a little or it would stall.
- When it surges, when I'm trying to increase throttle sometimes, it feels like it's not getting fuel (I'm no troubleshooting expert though); mostly cruises fine at constant speed, sometimes hesitates on throttle
- The only pattern I can see is when it's warmed up, at lower gears, and throttle but no climb in rpm (at low speed) in lower gears (but not all the time), until it jerks with a pull - not consistent (not every red light or not every gear change)
- this only started happening after I had a local indy install one of those Easy clutch kits (for that he had to remove the exhausts, transmission case, primary cover).

I'd brought it back to him describing as best I could and he thought it was a slipping clutch. He checked all the plates and they're all good. He said he couldn't really replicate the symptoms on a test drive. THe drive home from the shop was ok but then it started again yesterday. When I parked it I thought I definitely smelled a 'stronger' (?) exhaust smell than I usually smell.

Any ideas? I might have to break down, suck it up, and bring it to the dealer? That makes me shudder thinking how long it would take and what they'd charge trying to start diagnosing based on the above. First time - and growing more frustrated - Harley owner.

 

Usually if symptoms start after a modification then that says something. The way you explain what's going on though does sound like it could be two different things going on. So the guy that installed the easy pull says the clutch is good? Hmmnn. I'd be suspicious. If it revs while rolling and doesn't go faster that's usually a slipping clutch symptom. But if it wants to die at a stop that sounds like maybe a throttle body issue. Maybe clean the IAC ? Also, start the bike in gear with the clutch pulled in. Does it move forward? Lots of things to check but you have to start somewhere. Those easy pulls aren't great, they change the geometry of the linkage and sometimes just can't be used on some bikes.

 

The highlighted issue is almost always the clutch.

I guess it could be the rear belt is too loose and the drive belt teeth are slipping, or something broken in the trans so that the gears aren't meshing properly...???

But if the bike is in gear, the rpms go up, yet speed does not increase "until something catches/engages and it surges."
IMHO... It can only be one of three things.... The clutch, transmission gears, or the rear drive belt/pulleys. Something in the drive train is loose, broken, or slipping for that to happen....

Since the Indy replaced the clutch ramp, it's possible he messed up the engagement of the clutch somehow, but not sure exactly how that would lead to your symptoms...

You may also have a second problem with the way the engine is running, lack of throttle response, and smells of exhaust, but an engine WILL NOT increase RPMs in gear, and NOT gain speed.... unless something is disconnecting/slipping in the drive train...

Please report back when you get this figured out.... Based on your description, I'm stumped...

 

What type of oil are you running in the primary?

 

This is the problem ....if there was no problem before ...as you stated ...
the clutch is slipping or engaging too soon...cuz the adjustment is way off ...
if your sitting at red light with the clutch pulled in and it wants to stall ...the adjustment is off ...
take it back and demand he fix it or put everything back to stock !!! do not let him get away with you $$$ cuz you will be fighting this for ever !!
which is what he is doing ...(now you need something else) it will never stop (especially if you don't know anything about it yourself )
IMO..no ez pull clutch ...throw that **** away ..!!! this kind of problems is all they are good for ..!!!
The bike is useless in this condition..!!! after you paid for it !!!
Tough ..i know ..but true

 

The very first thing I would look at is the belt. Gets worse as it gets hot, slips, and then catches - Take a look for missing teeth and rubber dust and fragments and give it a push to see that it has tension. If it looks to be fine - I agree with the above and take it to "the guy" that did the work and have him ride it enough to feel what it's doing.

 

While there is some truth to the "problems is all they are good for" in your statement about EZ pull clutches, I have to respectfully disagree with the part that says, "all they are good for"....

With the clutch cables, the easy pull devices basically change the angle of pull of the inner clutch cable ramp. Harley has actually changed that pull angle a few degrees over the years with good results.

The trade-off to changing that angle, is that you decrease the "sweet spot" for proper clutch adjustment, and can make the clutch adjustment a little finicky.

For a stock & Stage I bike, unless you have an injury that affects your ability to pull the clutch, I wouldn't advise using one....

But if you do have a higher HP build and need a heavier than stock clutch spring to alleviate clutch slipping, some of the easy pull devices can make a big difference. Especially if you live/ride in an area where you encounter heavy rush hour (ie: stop & go) traffic.

I have one currently on a cable clutch with a big bore, cam, and head work build. I went to a stronger spring and the easy pull device has worked flawlessly for 15 years, with no issues.

I also had one on a 2012 Bagger, Stage II that I no longer have... It performed flawlessly for 5 years until I sold that bike....

So IMHO, they have worth, can make a noticeable difference in clutch pull, and can be reliable... albeit maybe a little tricky to adjust the clutch, and not all EZ Pull devices are the same..

 

A friend had one installed at a bike week in MD. It worked great for a few weeks then it started to slip. He had to pay to have it uninstalled and put back to stock. I believe he had the recluse installed by the authorized installer. The installer had his kids working for him and that might have been the reason for the eventual failure.