HELP! Clutch problems

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Feb 12, 2011 | 08:50 PM

#11

NickD

Road Master

Joined: May 2007

Posts: 899

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Something sounds weird, and now not in the clutch cable or the ramps. The clutch is normally disengaged all the time (meaning the clutch pack is pressed together and will always move the bike) unless you pull the clutch lever in to engage the clutch. That's when the clutch push rod pushes the sprung pressure plate out allowing the clutch discs to slip by each other. How (really where) are your clutch springs adjusted? Maybe they are out too far and not putting enough force on the pressure plate. If there are shoulders below the nuts (on the spring bolts) turn the nuts in until the shoulders are flush with the face of the pressure plate. (Run those in like you tighten lug nuts on a car wheel, one side than the other side all the way around.) That should ensure the clutch pack is compressed enough to move the bike. Start it up again in neutral and drop it into gear (be ready on the front brake!)

If the bike moves now go ahead and re-adjust the clutch push rod (all the way in and back it out a half turn and lock it down with the lock nut.) Then take the slack out of the clutch cable. If everything is still working but the clutch lever pull is too hard start backing out the clutch springs a couple turns at a time until the clutch effort is acceptable but everything else still works. Once you get it in the ball park and working then you can start dialing it in. Sometimes that clutch push rod needs a half turn out, sometimes a quarter, and sometimes way more or way less depending on the vagaries of your setup. Same with the adjustment on the clutch cable. There is no specifications other than you must make it work right.

You've won interesting problem of the weekend! So keep us posted!!!

Last edited by NickD; Feb 12, 2011 at 11:12 PM.

Feb 12, 2011 | 09:42 PM

#12

VonRizzo

Thread Starter

Novice

Joined: Feb 2009

Posts: 18

Likes: 0

From: Las Vegas, Nevada

Yep tried it...

Quote:

Originally Posted by tlb

Well that sucks, try adjusting the way this link explains it.
https://www.hdforums.com/forum/trans...-easy-way.html

I tried this one... No go... back at it in the morning...
Thanks...

Feb 12, 2011 | 10:50 PM

#13

tlb

Elite HDF Member

Joined: Apr 2007

Posts: 4,984

Likes: 8

http://www.ehow.com/video_2330184_ad...utch-pack.html

http://www.ehow.com/video_2330185_ad...4c2b9b421&cp=1

Feb 12, 2011 | 11:26 PM

#14

NickD

Road Master

Joined: May 2007

Posts: 899

Likes: 10

Never pull the rubber boot down on the clutch cable (like in the video) to get to the adjustment nuts. Always pull the rubber boot up! (And support the other end of the cable with your hand when doing so!) Pulling the boot down stretches (sometimes even rips) the upper part of the boot and that's the part that keeps water (and whatever else) from running down into the cable.

Feb 13, 2011 | 06:44 PM

#15

VonRizzo

Thread Starter

Novice

Joined: Feb 2009

Posts: 18

Likes: 0

From: Las Vegas, Nevada

Hey everyone... Good news got the clutch adjusted on the first try this morning... I do appreciate all the advice thanx for the tech info I'm a tech guy and like that I was able to eliminate things that where not affecting the adjustment. I think it was a combination of the starting it up and putting it into gear and a lighter touch with push rod adjustment. I used the method of holding down the lever and turning in the screw till the lever moved away from the bar, but I did with much less force than I had use the first time.

I had great ride today, with just a slight adjustment in the cable slack but I may put the slack back in it I think I prefer it like that...

Thanks again to everybody for the help... HD Fourms is the best...!!!

Feb 13, 2011 | 08:15 PM

#16

NickD

Road Master

Joined: May 2007

Posts: 899

Likes: 10

Ride On!

Feb 13, 2011 | 08:32 PM

#17

tlb

Elite HDF Member

Joined: Apr 2007

Posts: 4,984

Likes: 8

Glad we could help. The first time I adjusted my clutch pack it took me several tries to get it adjusted. Half of the fun of owning a Harley is being able to work on it myself.
I grew up on a farm, where I learned to work on everything from wiring a house to replacing clutches. Anymore, I do not even change the oil on my cars.