Ironhead another clutch adjustment problem

[Pigthang]

This is the first thing i did when i got my bike. I didnt know ho to do it and i still can not figure it out for my life. Well any way. The first time i tried i ended up breaking the ball and ramp set up. The hook that holds the clutch cable yeah.... i snapped it.... Ordered a new one got it in and my brother adjusted it for me. Well since then ive done a lot more to the bike by myself and figured i could do it myself this time. Thats what i get for assuming. I adjusted it i thought all was good then hear a pop and the clutch cable is now not hooked to the ball and ramp setup. I dont think i popped the ball and ramp this time but i need help. I loosened up the cable all the way into the primary. i tightened down the screw inside the primary window till it got difficult to turn so i did the recommended 2 more turns. i released the lock washer and backed the screw out till it was a little loose then back in till there was no more wiggle with it. i tightened the lock washer back on and tested the clutch it wasnt disengaging all the way when i pulled the clutch in so i kept trying to get the setting right. the last time i tried the cable came unhooked. I'm guessing that i should take the primary off and see whats inside. what do you guys think? did i do something wrong? Maybe i just loosened the cable too much and it just came unhooked.

[asasial]

do you have an resistance when you pull the clutch lever in? does it feel like it does normally or at least something like normal

[Pigthang]

not any more the cable came out. but the first few times i tried adjusting it it felt normal

[72 Ironhead XLH]

with the cover off ,screw in the cable adjuster in the primary case to give slack. Using grease to hold the ball ramp in a fully seated position install cover.Screw adjuster STUD in untill resistance is felt, back off slightly, using a spark plug socket with the hex head, insert a screwdriver thru thru socket to the stud and hold stud in place. snug the locknut with the sparkplug socket. remove the excess cable slack with the CABLE ADJUSTER in the primary case.

[IronMick]

Originally Posted by Pigthang

... I loosened up the cable all the way into the primary. i tightened down the screw inside the primary window till it got difficult to turn so i did the recommended 2 more turns. i released the lock washer and backed the screw out till it was a little loose then back in till there was no more wiggle with it. i tightened the lock washer back on and tested the clutch it wasnt disengaging all the way when i pulled the clutch in so i kept trying to get the setting right. ...

This sounds to me like you do not have the factory manual or are not following it exactly. It is a very detailed process, 5 steps, some with a few parts. Must be precise.

[Pigthang]

I followed exactly what the manual tells me to do i think that im misinterpreting something along the way. And nothing broke this time the cable just fell out of the hook on the ball and ramp. This is my first bike and i try to do mostly everything myself to learn once i learn how to do it i should be set. Im glad i took off the cover anyways it looks really dirty and was low on oil. while its apart im going to try to clean it out a bit.

[asasial]

here's an easy mod for keeping tabs on the primary oil and it only costs about 5 bucks

[nativebroncofan]

Originally Posted by asasial

here's an easy mod for keeping tabs on the primary oil and it only costs about 5 bucks

I'm interested.
Please explain the mod or link to a post about it.
Cheap and easy that right up my alley.
WHATTSITDO????

Pigthang, try this link for another explaination on the clutch adjustment.

http://xlforum.net/forums/s...ad.php?t=70728

NBF

[asasial]

here ya go hope it helps.
http://xlforum.net/forums/s...67#post2874067

[Pigthang]

Originally Posted by runingmouse

One of the first things I had to change was my clutch. When I first got my bike. I installed my disks and adjusted per the FM. I had very little pull at the lever, and it would not fully release. After opening the primary up 2 more times and trying to figure what I had done wrong. I understood I had to first make sure the ball and ramp was fully released. (to do this while the cable is slack, you push the cable into the primary a little.) And nowhere in the FM is this part listed.

So If the FM way don't work for you, like me. There's somthing to think about. The ball and ramp mech. don't have a return spring.

I think this is my problem. All i did was put the clutch cable adjuster all the way into the primary and then tighten down the ball and ramp adjuster. It didnt even run across my mind that the ball and ramp set up doesnt have a spring.

When i pushed the cable adjuster all the way in i guess i accidentally unhooked the cable and possibly even the hook that holds it on.

also im not sure how far i screw the ball and ramp adjustment in. what exactly is going on when that happens? i screw it in till it gets pretty difficult to turn then turn 2 more times