[Tnicean]

HI folks,
I need some help. I was adjusting my clutch. (maintenance - was working ok) This time I took all the slack out of the cable before loosening the nut and adjusting the little allen head clutch adjusting screw.

I used the allen wrench to back off the screw then screwed in back in till it was touching, did it a couple times to make sure my touch was right and worked the clutch lever a few times.

Now it feels like something has come loose inside and I can't seem to take the slack out of the cable and the clutch does not move like I know it should when I pull in the clutch lever.

Could the ball bearings in the clutch have come out of place because I put too much slack into the cable. Could the ramp on the other side have come out of place? Any help will be appreciated greatly. I am ready to roll it on the trailer and take it to the shop.

I have the manual but I have done this a few times before with success so I didn't read it before I started. Book says put a lot of slack into the cable but doesn't say to loosen it all the way. I think this must have been the error, but not sure. Thanks.

Tnicean

[aaron]

It dosent sound like anything major. You may want to pull the housing on the other side where the cable goes in and check the cam and balls. I have never had a problem when backing the cable ALL the way off. Something came loose or broke.

[Killer-B]

Tnicean, clutch adjustment is easy if you have the maintenance manual...

[CD]

You took the slack out of the cable before adjusting the clutch adjuster?

"This time I took all the slack out of the cable before loosening the nut and adjusting the little allen head clutch adjusting screw"

If you took all of the slack out of the cable, that is the exact opposite of what you need to do.

http://www.directparts.com/static/ar...djustment.html

The reason you adjust the clutch end of the push rod is not to add or decrease cable slack or lever play. The reason is to set the free play between the pressure plate and the throw out bearing. Too little free play will wear out the throw out bearing quickly. Too much free play requires excessive movement of the release arm ramp. By collapsing the adjuster you remove all tension on the clutch arm so that when you seat the adjuster several times, the release arm is fully back. After you get the clutch adjustment correct, adjust the cable so the lever play is where you like it.

[Tnicean]

Thanks for all the replys. I will take another whack at it this weekend. I was adjusting the clutch as part of my 30K maintenance just before I was going to ride to my parent's house for my Pap's 82 birthday party last Saturday. When my adjustment went to hell, I had to go to plan "b" and take the cage instead. Bummer. My 3 brothers were there with their Dyna, Fatboy and Heritage Classic. I felt naked without my bike. I'll let you know what I find when I have some time to look at it again. Have meetings all this week at work and it wears me out too much to work on it in the afternoon. Thanks again,
Tnicean

[Tnicean]

Well, I finally had time to work on the bike. I took the transmission cover (where the cllutch cable enters) off and the mechanism was hung all the way open, like the clutch lever had been pulled all the way. It may have been hung up on the transmission dipstick - I may have crossed it over the clutch cable when I put it in - not sure. I did have a hard time getting it started into the hole when I changed the oil. Anyway, I freed up the cable and reset the lever and the clutch rod. Now all is well. Also, while I was working on it, I pulled the cam cover to look at the cam tensioners. I have 28,800 and they were worn somewhat less than halfway. The book says they should be serviced when they are worn half way. I figure I have about 10K more miles to decide what to do. I will probably go iwth the gear drive cams. I also installed the baisley spring while I was in there. I worked about 5 hours getting everything straight.

I did have one screwup. I started to refill the transmission and when the pepto bismol looking Redline Shockproof Heavy started to run next to my feet I realized I had messed up. I should have just put the measuring container back under the bike to catch the oil, but I didn't think of that. I just kept trying to start the plug. By the time I got it started, I had lost alomost all the oil. Didn't have enough left in my quart to completely refill the trans, so I'll have to wait till Monday to get enough to fill it up. I won't ride it till then. I did start the engine and the oil lirght went right out, so I must have gotten the spring in correctly.

All is well now. I'll be riding again on MOnday.
Thanks for all the replys.
Tnicean

[Killer-B]

Yup, I new it would be obvious. There is nothing hard or to fear about working on a Harley, all you need, is a manual and common sense.
Good for you.