I have a 2006 Ultra Classic with a CSC trike kit. It also has a manual reverse installed that never since I bought it used. I had ridden the bike the previous day and intended to change the primary oil and adjust the clutch. After draining the oil I loosened the clutch cable and adjusted the clutch turning the center screw out a half turn. After turning the cable adjustment so that there was a little slack in the clutch lever, I noticed that the clutch lever would no longer pull all the way in. After going back and forth and thought that something in the cover where the clutch cable comes in, was binding. I removed the dipstick and saw that the dipstip was broken off. Thinking I had my problem I removed the cover, removed the broken off dipstick and checked that I had movement of the ramps which I did. Put the cover back on and still binding. I had a new clutch cable and replaced that, no change. Checked the rod that goes from the ramps to the clutch and everything moved freely. Took the clutch pack apart and checked everything and it all seemed good. Still no change, I had a Burley Brand EZ Pull kit on it so thinking maybe that was the problem so I took it off, still no change. Lastly, in order to get the clutch lever full adjusted so there is very little slack, the clutch cable is it the very end of adjustment. When I pull the lever, it goes in halfway and then completely stops. Any suggestions or idea are appreciated.

 

I put in a Jims? dipstick . My 01 had groves from cable rubbing. There was some discussion years ago about dipsticks breaking off.

As for discussion, my first assumption was ***** came loose. I did this once by playing with lever when clutch was off,

Clutches are a bit of voodoo. Sometimes I adjust a couple times, until they feel right. Mechanice told me to run in and out a few times, to get any crud off, before doing your turn out. But I got nothing of help on this.

The piece you pulled out of tranny added up to the full length? Also make sure snap ring for clutch is fully in grove if you took apart. That had bike engaging on me, but lever ok.

But if everything was working before you took apart, I have to wonder.

What would a bad throw bearing do? The bearing like thing between ramps and cover. Cause it reminds me of stuck *****.

 

I believe that the Bully ez clutch is what caused the dipstick to break off. The added length causes the cable to go where the factory didn't intend. Also, just for the hell of it I screwed the threaded rod in the middle of the clutches in further and the problem is solved. When I originally adjusted the clutch, I screwed the rod in by hand till I fel resistance and assumed this was hitting the push rod but it wasn't. When I screwed it in until I felt it stop, the clutch worked as before.

 

My stuck 5 speed, the cable was rubbing on dipstick. Enough to matter? Dunno. But years ago there were threads about, and enough for peoole to try and sell you aftermarket dip sticks


How does ez clutch change dimmensions? Isn't it just the ramp angle?