Good morning all,

Yesterday I needed to replace my starter on a 2003 Ultra Classic. After pulling the starter and proceeding to replace I came to realize the coupling for the jackshaft fell behind my inner primary. After pulling out my clutch and inner primary I went to reinstall everything and when tightening the clutch nut I saw the clutch pushrod start to slide out. Thinking no big deal of it I simply pushed it back and proceeded to put everything back together. Then when I set my clutch adjustment I went to pull the lever and it was a wet noodle now. I couldn't tighten it with the cable adjustments either at this point to make it tight again???

Could the cable have disconnected within the transmission housing? I haven't a clue why that would happen.

Any advice is greatly appreciated.

 

The is a 3 ball ramp on the right side, under that cover that needs to be put back where it belongs. It's been over extended. (Hint, Never pull the clutch lever when the clutch is apart.)

 

Thanks for the info Stiggy.

I shouldn't be concerned about seeing the clutch pushrod come through the clutch adjuster?

 

It's been awhile since I messed with the clutch on my 2003 Heritage, and the last few clutch jobs were on hydraulic clutches... I had to reference a 2003 bagger clutch parts diagram to refresh my memory...




When you say "clutch adjuster" do you mean the #15 release plate....?

Are you saying that the pushrod is coming through the #15 release plate (#37903-90)....?

That should not happen.......

The #5 clutch release pushrod (#37088-90) fits into the #6 left push rod end (#37090-98A). The amount that the pushrod end is threaded into the release plate is your clutch adjustment. The #2 bolt at the end (#7848W) is just the locknut to hold the clutch adjustment...

For the #5 rod to come through the release plate, either the threads of the pushrod end are not engaging with the release plate, you have stripped out the threads on the release plate, or you forgot the left pushrod end to thread into the release plate...

If the pushrod is coming out, still attached to the clutch release plate.... you have removed and not replaced the #19 internal retaining ring... That should about cover it..

Make sense? Or did I misunderstand what you are saying..?