How to adjust your clutch (05 and newer)

Energy One
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surferdude

surferdude

dry docked
Well ... got some bad news ... for me ... but obviously not the first ... I talked to Nelson and the guys at Strokers ... those guys are great ... they were busy yet had the time to "educate" me about the pushrod, clutch etc. I pulled off the primary inspection cover and did not like what I saw ... I did the 10k primary fluid change and now at 13k the fluid is all gray and something was grinding and wearing out. So far the bike is running good but sooner or later something will break or just stop working. I called the service guys in Prescott and they said that it should take about 2 hrs to replace the clutch carrier and put in a new clutch ... I would attemp to do it myself but I'm not that confident yet. I see that some of you have put in the Bandit clutch .... any other suggestions? :D Thanks ...
Also since I'll have the clutch all apart what else should I be thinking about?
 
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lee

lee

Well-Known Member
IF your clutch needs replacing, I would of thought the Bandit would be the way to go - there is a how to on here by Jake on installing the bandit - read it through a couple of times before you decide on paying the extra for someone else to do the work. I'm sure Jake will also help you out with any issues as he has done this already.
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
It is 1/4 turn (as Raywood and other pointed out) after all free play is taken out. Make sure that when you tighten the lock nut (6-10' lbs.) That you hold the adjusting screw to make sure it does not turn.

Cable slack is 1/16"

Below is from Section 4-2 out of the BDM 2005-2006 Service Manual

CLUTCH AD,JUSTMENT PROCEDURE
Perform the following clutch adjustment at all service intervals.
1. Support the motorcycle upright and level.
2. Slide clutch cable adjuster boot out of the way of adjusting hardware.
3. Turn adjuster to provide maximum slack in cable.
4. Loosen pushrod adjusting screw jam nut.
5. Turn pushrod adjusting screw clockwise to take up all free play in pushrod.
6. Turn pushrod adjusting screw counter-clockwise 1 /4 turn.
7. Tighten pushrod adjusting screw jam nut to 6-10 ft Ibs. Do not allow adjusting screw to turn while tightening jam nut.
8. Adjust clutch cable to provide 1/16" free play at clutch lever.
9, Tighten clutch cable adjuster locknut.
10. Return clutch cable adjuster boot to original position.
 
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surferdude

surferdude

dry docked
Yup ... that's what I've done and on a worn out pushrod or broken something it won't engage the clutch. Lee had the same problem and like he had to do I had to back it out 2 1/4 turns before the clutch will engage ... I kept the allen wrench in the adjusting bolt to make sure it wasn't moving. I think I will go with the Bandit set up .... So in the next few weeks I'll get the parts and re-read the how-to ... Does anybody know why this is happening on so many 05's???? :confused: :eek: :job:
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
Not sure what you mean by happened on so many 05. It has occured but I do not think it is a very big on-going problem, at least no more than any other years. Could be wrong but have had no issues with mine.

It may be just making sure that one does it often enough to keep up with the maintenance schedule and not letting it go and then have it more likely to fail. Should be checked and adjusted every 2500 miles according toe my O & M Manual or same time frame as oil and filters.
 
G

Gas Man

Cool isn't cheap
Calendar Participant
reason... fucked up carriers.

and on the freeplay once the clutch rod is adjusted... just make the lever hold a dime. Al taught me that trick... works great!
 
W

waykool

Banned
tacoloco said:
My shifting was hard and finding neutral was difficult. After adjusting my clutch, my shifting is now smooth and finding neutral is a breeze. This is how I did it. After leveling the bike, slide the clutch cable boot to access the cable adjuster

Finally adjust your cable to give your clutch lever 1/16 of free play. Tighten the jam nut and slide the boot back in place.
Enjoy your smooth clutch. If this adjustment doesn’t do the trick for you, consult your near BD dealer.:)
Click to expand...
After tightening the jam nut should Lok-Tight be used? I just got back from getting my dog serviced at Tampa Big Dog. They said that they adjusting the clutch and all seemed good when i left the dealership. But on my way home the clutch adjuster vibrated loose. This was not a good thing. When pulling off the highway onto the off ramp I noticed that I had no clutch. Almost rear ended the car in front of me and nearly got rear ended by the car behind me. Like I said, Not good. Didn’t have any tools with me so I adjusted it as good as I could by hand. Vibrated loose once more on the rest of the way home. Needless to say now its back to being hard to shift and I still cant get it into neutral.
 
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lee

lee

Well-Known Member
same thing happened to me recently. I just tightened it back up when I got home and its been fine. I doubt you should put loctite on it - I certainly don't. They probably forgot to tighten it properly after adjusting it.
 
W

waykool

Banned
lee said:
same thing happened to me recently. I just tightened it back up when I got home and its been fine. I doubt you should put loctite on it - I certainly don't. They probably forgot to tighten it properly after adjusting it.
Click to expand...
Ahhhh.... I see. No thread lock needed. Thank you.:D
 
Raywood

Raywood

The Pirate
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waykool said:
Ahhhh.... I see. No thread lock needed. Thank you.:D
Click to expand...
You expand the adjustere till you have 1/8" of slack/gap at the clutch handle lever. Take out a bit more if you like it snug.
This adjustment is only for the lever not the clutch although if there's too much slap you won't get full acuation of the clutch rod.

:cheers:
 
Keith S

Keith S

EHC FREE!!!!
Does anyone have the how-to for adjusting the clutch on the LSD models? Is the pushrod adjustment in the center of the clutch under the primary cover?
 
pig pen

pig pen

Well-Known Member
Keith S said:
Does anyone have the how-to for adjusting the clutch on the LSD models? Is the pushrod adjustment in the center of the clutch under the primary cover?
Click to expand...
yup. Most adjustment can be made on the cabel, 1/8 inch of play in lever.
 
DRBarnhart

DRBarnhart

Insert title here...
Keith S said:
Does anyone have the how-to for adjusting the clutch on the LSD models? Is the pushrod adjustment in the center of the clutch under the primary cover?
Click to expand...
The primary looks the same as a Harley which would mean your right, the adjustment is under the derby cover.

The actual adjustment procedure will be the same from there.

Dennis
 
REMorris

REMorris

OK Rider Shakey
BDM dealership, Iron Lightning says the adjustment procedure for my 2009 Mastiff, is totally different than this procedure.

So, if you have an 09 model, get the new instructions first.
 
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