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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #1  
Old 29th April 2018
THEWILDONE THEWILDONE is offline
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Default Clutch WILL NOT adjust to disengage!

I have a 2003 1200 sporty. I have had very few problems from this bike....

Recently I have been having problems with the clutch not disengaging.

I have adjusted the clutch per the FSM MANY MANY times. I probably adjusted it 20 times yesterday alone.....

The problem is no matter what, I cannot get the clutch to fully disengage when the lever is pulled in. It also gets worse as the bike heats up.... Sometimes it's a problem when it's cold, sometimes it isn't but when the bike is heated up it's definitely a problem....

I put a Barnett extra plate clutch kit and diaphragm spring in several months ago and have ridden it with no problems since then...

I recently put Harley brand mini apes on the bike and longer Drag Specialties cables to go with the bars..... It seems like ever since I put these new bars on that's when I started having problems with the clutch disengagement.

I'm tempted to pull the side cover completely off and see what's going on in there.

Please someone help me figure out why adjusting the clutch per the FSM just isn't working. I adjusted the clutch that way many times without problem when the bike still had the factory drag bars on it but now that the apes are there it just doesn't seem to want to work. Could be unrelated to the problem I don't know.
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  #2  
Old 30th April 2018
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Default

Here's the Sportsterpedia section on the Clutch:
http://sportsterpedia.com/doku.php/t...vo:priclutch01

Pay particular attention to the Release Adjustment - Why & How...

Did you replace the Release Bearing when you changed to the extra plate kit? If not, perhaps it is now malfunctioning...

The cable & release mechanism can be removed/examined without removing the Primary Cover - Check the release bearing & the ball & ramp mechanism...

Did you get the spring & lock nut back in correctly?

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  #3  
Old 30th April 2018
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Default

sounds like either a) stretched cable or B) bad bearing. take off the cover. the bearing should not have any side to side movement.
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  #4  
Old 30th April 2018
THEWILDONE THEWILDONE is offline
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Default

After hearing you guys I'm 99% confident the problem is in the release bearing!

I pulled the primary off and didn't see anything irregular other than the release bearing. I removed it from the clutch basket and it is SUPER wobbly and gritty feeling.... That has to be the culprit!!!


I found a thread about the release bearing on the forum here and ordered a package of 7200B bearings.

Thanks guys! New bearing should be here tomorrow so I'll know for sure shortly.
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  #5  
Old 4th May 2018
THEWILDONE THEWILDONE is offline
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Well I got the new 7200B bearing in there and everything seems good again!

Thanks for the input fellas, I'm glad I found the thread where you posted specifically about this problem on your bike Redd.... Is your 7200B bearing still going strong??
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  #6  
Old 6th April 2019
THEWILDONE THEWILDONE is offline
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Default

UPDATE!

The bearing (7200B) I put in there almost a year ago crapped out!!!

The bike started to do the same thing as last time, clutch wouldn't disengage properly after adjusting per FSM, and it was also hard to get into neutral at a stop.....

After removing stuff to get to the TOB, the little bolt that goes through it with the snapring retaining it was loose!!!!!! The bearing itself was the source of the play.

Amazon sold me two 7200B bearings last time so I just slapped the 2nd one from my order last year in there and it's good again it seems.

I think I need to source a higher quality bearing for next time, although, changing it out ever year or so isn't bad at all, it's easy enough.
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  #7  
Old 6th April 2019
Tomcatt Tomcatt is offline
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I just put in a 7200B when I got rid of the clutch damper plate. I got the better FAG bearing instead of the cheapy Amazon 2 pack. Sure you got it installed the right way? Even the cheapies should out live the misused OE bearing.
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  #8  
Old 6th April 2019
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Quote:
Originally Posted by Tomcatt View Post
I just put in a 7200B when I got rid of the clutch damper plate. I got the better FAG bearing instead of the cheapy Amazon 2 pack. Sure you got it installed the right way? Even the cheapies should out live the misused OE bearing.



in case you haven't seen it, while not exactly written properly, it does show the correct and in correct orientation.

http://xlforum.net/forums/showpost.p...8&postcount=27
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  #9  
Old 6th April 2019
Tomcatt Tomcatt is offline
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Quote:
Originally Posted by ReddTigger View Post
in case you haven't seen it, while not exactly written properly, it does show the correct and in correct orientation.

http://xlforum.net/forums/showpost.p...8&postcount=27
Good pics but that doesn't mean THEWILDONE got it right. Get it wrong and the bearing will fail prematurely.
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  #10  
Old 6th April 2019
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if it is an angular contact bearing, it must be installed correctly, the regular deep groove bearing are not.

https://www.skf.com/group/products/b...ngs/index.html
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