Lost clutch question

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Sep 4, 2012 | 08:31 PM

rg_dave

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From: Cypress, TX

Lost clutch question

Today riding into work my clutch went away as if the cable broke. Up until that point my clutch worked perfectly. I managed to ride back home with no clutch (fun trick in Houston traffic). Checked it out tonight and cable is good. Pulled the derby cover and lock nut was loose and had backed off. I'd go bitch at my mechanic but since it's me I can only blame myself. I did tighten it down to specs using a 17mm spark plug wrench. Now I can't adjust the clutch to get slack out of the cable. If the adjustment bolt backs does something need to be reset on the transmission side? I won't be able to pull that cover until Friday.

Last edited by rg_dave; Sep 7, 2012 at 11:10 AM.

Sep 4, 2012 | 08:33 PM

mkguitar

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From: Phoenix '53, '88, '09 Big Twins

probably the ***** fell out of place in the ramp mechanism.

Under the tranny end cover

a manual would be a good buy right about now

torque spec for the tranny end cover bolts is now 25 ft pounds

first try this:

bike at room temperature

open derby cover

Loosen jam nut on clutch adjuster
screw.
Turn adjuster screw at clutch inward until
lightly seated.

Back out adjuster screw 1/2 to 1 full turn. While holding
adjuster screw, tighten jam nut to 72-120 in-lbs

Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.

Turn cable adjuster away from jam nut until
slack is eliminated at hand lever.

Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8 in. ( or use a dime/nickel) free play between end of cable ferrule
and clutch lever bracket

mike

Last edited by mkguitar; Sep 4, 2012 at 09:10 PM.

Sep 4, 2012 | 08:55 PM

rg_dave

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From: Cypress, TX

Thanks. That's what I was thinking. Just wanted a another opinion. I have a manual. Have adjusted clutch a several times before and changed the cable when I replaced the bars. I torque everything to specs but this time the lock nut loosened off. Mostly was wondering if the adjustment screw loosening off might cause the ***** to come out of their slot in the ramp and ball mechanism.

Sep 4, 2012 | 08:59 PM

mkguitar

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From: Phoenix '53, '88, '09 Big Twins

probably section 6.5 in your manual ( it is 6.5 in the 09 manual)----look at the ball and ramp- it is possible to reset manipulating the lever

I've been using a little locktite on the adjuster jam nut. I've had mine back off before.

now that you know what it feels like ( cause you'll get grabbing or slipping and weird lever feel) you can remedy that at the roadside before it becomes a problem

mike

Last edited by mkguitar; Sep 4, 2012 at 09:11 PM.

Sep 4, 2012 | 09:09 PM

stuart1270

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From: Bronxville ny

I believe the ramp and ball bearings are held in place by a large snap ring. Maybe impossible to come out of place.
Remember you can remove tranny cover without the ball bearings coming loose.

Last edited by stuart1270; Sep 4, 2012 at 09:11 PM.

Sep 5, 2012 | 08:33 AM

rg_dave

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From: Cypress, TX

Thanks.
Yes, they are held in place by the snap ring but they can slip out of their grooves. They don't fall out of the mechanism completely and bounce around. I had that happen when I originally installed the clutch cable and forgot to apply grease to keep them in place. They didn't fall out of the mechanism but it didn't work as it should. I'm going to try to reset it as Mkguitar earlier posted. If that doesn't work, I'll pull the cover and reset them. Hopefully, that's all I have to do.

Sep 7, 2012 | 11:11 AM

rg_dave

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From: Cypress, TX

Update
When the lock nut backed off the adjustment screw backed out and allowed the actuator to spin to a point where it wouldn't turn back. I pulled the right side cover realigned the actuator and reset the ***** in the ramp and ball mechanism. Adjusted the clutch and I am good to go. I couldn't find my spark plug wrench so I used a 17mm deep socket and a pair of vice grips to tighten the locknut very tight while holding the adjuster in place with the allen wrench. FYI, I got it snug with a wrench and was still able to tighten it quite a bit with the socket. Test road until hot and all is well. My advice to others is to always use a socket to tighten the locknut, whether a sparkplug wrench, welded wrench and socket, or the vice grip and socket method I used today. It might keep you from winding up in my situation. Riding through the city with no clutch is pretty tricky.