Dragging Clutch

[JasBass]

Well y’all…I think I got it. Got after it this morning and got it to where she finally releases. No slip and when I have the clutch in, she’ll roll back. It’s not free like neutral, but I think it’s where she’s going to be until I do the 9 plate and ramp setup. Oddly enough, when I changed the cable and cleaned/re-lubed the ramps and rod the effort is significantly easier. Guess she was gunked up.
Any tips and tricks for the inspection cover weeping? New gasket and she still wanted to weep. I’m not trying to ram rod this cover down and strip the threads..or is it just designed for that kind of pressure? Skim RTV?

 

[dtmmil]

How tight are the bolts? I use 8-10ftlbs on them.

 

[Jersey Big Mike]

Well y’all…I think I got it. Got after it this morning and got it to where she finally releases. No slip and when I have the clutch in, she’ll roll back. It’s not free like neutral, but I think it’s where she’s going to be until I do the 9 plate and ramp setup. Oddly enough, when I changed the cable and cleaned/re-lubed the ramps and rod the effort is significantly easier. Guess she was gunked up.
Any tips and tricks for the inspection cover weeping? New gasket and she still wanted to weep. I’m not trying to ram rod this cover down and strip the threads..or is it just designed for that kind of pressure? Skim RTV?

NO DO NOT force those screws down you will crack the ears on the inspection cover.
Be careful cleaning the area so that debris does not fall into the primary.
Clean the surface as best you can if that doesn't solve it, use some silicone.

 

[Jersey Big Mike]

54in/lbs then 108in/lbs for inspection cover screws according to manual. No Loctite

 

[Chong]

My experince on changing, lubeing new clutch cable on a 03 chopper ..
Background, put new cable in just before fall gathering. Pull was stiff .. Took it back apart, just at the handle bars. Used some PJ1 cable lube . And throughly cleaned the inner hand controls surfaces. The nylon pin (approx .375d x .625L) and machined slot for it was filthy. I cleaned all that real good and applied some lithium grease .

Pulls real nice now- butter , bit better then the 04 Bulldog which I was totally happy with.

 

[JasBass]

How tight are the bolts? I use 8-10ftlbs on them.

Got them at 15, that’s my limit. Bike already has the billet cover, so I wasn’t stressing about the cast corners cracking. I used a skim of RTV, I’ll let it cure and see how it goes tomorrow.

 

[dtmmil]

At 15 you might break the bolts or strip the threads, be careful.

 

[JasBass]

At 15 you might break the bolts or strip the threads, be careful.

Yep, that’s why I yelled uncle lol. We’ll see if it’s good to go tomorrow and if it still weeps I’ll have to reassess.

 

[Jwooky]

Also clean the primary vent to ensure it’s not clogged and pressurizing

 

[JasBass]

Anyone ever modify the primary inspection window for the 06-later ones to help the gasket seat better? For my 06, I have that funky two window deal that has different sealing heights. It looks like the weep is coming from left window that has that small drain in the bottom of it. No matter how snug I get it, it just doesn’t mate/seat into all of those different heights. I see the 07-newer ones just have a single window with a flush mating surface. I’ve been fighting this for two days now and I’m ready to make some RTV art or buy some cork and felpro gasket sheets and innovate . The photos are just randoms I found online as examples.