Stumped on the clutch

[ChopperFred]

Hi guys. After a search, I couldn’t find an answer to my issue so I’m putting it out to the Forum. I have a 2004 BDM Chopper since new (left side drive). I’ve been learning to service the bike over the years but consider myself an amateur in that area. Anyway, I just finished the 15K service including adjusting the clutch which I’ve done before. The problem is that with the rear wheel elevated, I cannot rotate the rear wheel by hand even though the clutch lever is pulled in. If I put the bike in neutral, I can rotate it easily. I repeated the clutch-adjust again, but nothing changed. I thought that perhaps the starter gear is not retracting so I pulled the outer primary, and it looks OK.


Could it be an issue with the clutch hub nut or the tranny ball and ramp? If so, what changed? The bike was running fine before.


Thanks in advance.


Fred

 

[woodbutcher]

how much trouble did you have putting it in neutral? wondering if the cable is pulling the clutch rod. sounds like it is the ball and ramp, but you said you checked that.

 

[KaptinAmerika]

That doesn't necessarily mean anything other than your clutch plates may be getting worn.
Without everything running, vibrating and warming up the viscosity of the primary fluid, which would cause the plates to release from each other, the plates could simply be sticking together which would still cause the wheel not to free turn with the trans in gear and the clutch lever pulled. Now if you use the clutch while it is running and it is not disengaging or it is creeping then you have an issue.

 

[ChopperFred]

how much trouble did you have putting it in neutral? wondering if the cable is pulling the clutch rod. sounds like it is the ball and ramp, but you said you checked that.

Thanks for the reply. It was not too difficult to get into neutral (engine off). And, no, I have not checked the ball and ramp. I did change the tranny oil, but did not open the trap door. So I don't know why the ball and ramp would change. Also, when I pull in the clutch lever, I can see the clutch "flexing".

 

[woodbutcher]

shot in the dark. pull the rod and take a look at the pointed end (the end that contacts the throw-out bearing) and see if it is worn out. the rod itself is case hardened and prone to wearing through that hardening. may not be the problem, but it could be a contributing factor. but while you are in there, make sure the balls in the ball and ramp mechanism are in the pockets where they belong. best way to keep them in place during assembly is with a good glob of grease.