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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #1  
Old 17th November 2013
John_43 John_43 is offline
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Default clutch is slipping..?

howdy. I have an 06 XL883 and I am stuck.


my bike "slips" in gear, and I can't figure out why. when the problem first arose, I was about to pull out of a parking spot and tried to accelerate. the primary made a really loud chattering noise and barely responded to throttle action, so I shut off the bike and opened the primary chain inspection cover. a bit of smoke was visible, and the clutch smelled like it burnt up.

I bought new clutch plates and a new compression spring and threw them in yesterday, but the bike still "slips"... It sort of behaves as if the clutch was pulled in while in gear. that's to say I can move the bike forward and back -in gear- without pulling on the clutch. it sort of stutters when it moves (in gear), as if something (?) was alllmost catching to keep it in gear, but then can't quite catch. the clutch cable is adjusted fine; I've done several readjustments to be sure.

I think this is an unrelated problem, but in addition to that the bike isn't kicking over. when I hit the starter, I hear mechanical action but it doesn't get the bike going. I'm pretty sure it's just fouled plug(s), but haven't looked into it much yet.

any help is appreciated.
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  #2  
Old 17th November 2013
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Default

Did you remove the spring plate and replace with extra plates?

Did you check the total height of all the clutch plates?

Did you verify the splines on the clutch basket were not worn with grooves from the clutch plate tabs which prevent the plates moving enough to engage?

Did you verify the ramp adjustment completely released the pressure of the clutch plates when the hand lever is let go?

The adjustment in the clutch cable is used to set hand lever free play after the ramp mechanism at the clutch is adjusted. Did you do that correctly?
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  #3  
Old 17th November 2013
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Default

checked all of the above, and double checked. Still the same problem. I think it's somewhere in the gears (sorry for the vague terminology, I'm unsure of what exactly to look for)? the stuttering doesn't seem to be from the clutch the more I look at it. it feels like the bike is catching a gear, but can't stay engaged. it definitely has the same problem in 1st and 2nd. any idea what else to look for?
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  #4  
Old 18th November 2013
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Default

There was a thread a bit back that showed the main drive pulley having been stripped...

The teeth on the inside of the pulley were toast. Ill try and find it for you.

The starting issue might be the battery. Stock battery?

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  #5  
Old 18th November 2013
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Default

yeah, stock battery. but lights work, not weak or anything. also the starter seems to be functioning fine, just no response in the motor... which is why I suspect plugs.
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Old 18th November 2013
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http://xlforum.net/forums/a...t-1677251.html

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  #7  
Old 18th November 2013
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[QUOTE=pat5150;4642052]There was a thread a bit back that showed the main drive pulley having been stripped...

The teeth on the inside of the pulley were toast. Ill try and find it for you.

i sort of don't think it's that, since when I roll the bike the belt turns normally. but that IS with no load on it from the motor. So I'll check it to be sure.
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  #8  
Old 18th November 2013
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Sounds like you have two unrelated problems. Sounds like you need to have a good mechanic look at it before the damage gets even more expensive.
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