Clutch won't release
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Road Warrior
Joined: Oct 2006
Posts: 1,350
Likes: 46
Clutch won't release
1999 Ultra, installed a new belt, adjusted the clutch so it has a 1/2 turn of free play, now the clutch won't release. I had the primary off, the only thing I can think of is if I left the nut holding the clutch assembly loose. I guess the only thing I can do is pull the round cover off & remove the snap ring & check it. Good thing it's been cold & snowy. Unless someone can think of something else. I took all of the slack at the cable end, still no release. I did not pull the clutch basket apart at the time.
Toby
Toby
Grand HDF Member
Joined: Jan 2012
Posts: 4,459
Likes: 2,892
From: Oklahoma
It is not clear in your write up if the clutch worked properly for awhile and now won't release or if this is immediately upon reassembly. The derby cover will need to come off regardless and if you are not confident the clutch nut is tight, that will worry you until you have rechecked it. Without removing the primary cover you won't be able to lock the clutch and primary sprocket to verify the torque on the clutch nut. I don't recall the clutch nut torque value, you might be able to put the transmission in gear and have someone hold the rear brake to check the nut torque. The other possibility is a burr on the threads of the adjustment screw made a bind that you believed was the plunger contact point, but in reality, rather than a half turn out you are several turns out. Repeat the clutch adjustment procedure (slack cable) and run the adjustment screw in and out several times with a wrench to be sure the threads are smooth, then go your half turn out from the contact point and set the lock nut. If that doesn't get it, you may have a problem with the ramp and ball release mechanism inside the chrome cover on the opposite side of the transmission where the cable goes in. There are descriptions in the maintenance section about clutch adjustment and resetting the ball and ramp without having to remove that cover. That plate inside the snap ring that has the adjustment screw going through it is always slightly loose when the clutch lever is all the way out. You can wiggle it slightly and see the movement. When the adjustment screw makes contact with the release mechanism, that looseness in the plate disappears. That will confirm you have really found the contact point with the adjustment screw. If you believe you have found the contact point but that plate is still slightly loose, you haven't really bottomed the adjuster screw yet, keep turning... Good luck, hope it is an easy fix.
Road Master
Joined: Mar 2021
Posts: 852
Likes: 374
From: Toledo, Ohio
Check the sticky thread about adjusting the clutch the easy way. Thats the way I do it. It makes sure your at the right point before your half to 3/4 back turn. With your cable completely loose and lever to the handle, hold slight pressure on it while you turn the adjuster screw. Once you feel a slight lift on the lever, go a half turn back and lock the nut
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Road Warrior
Joined: Oct 2006
Posts: 1,350
Likes: 46
I pulled the derby cover & checked the nut, its tight. Readjusted the clutch, seemed to still be holding. Started it up on the stand, reve'd it up & down a few times & hit the rear brake with the clutch in & it seemed to get it freed up. Thanks for the help. got about 20 miles in yesterday for it's maiden voyage after installing the new belt & 2009 up rear swing arm.
Toby
Toby
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