| Author | Message | ||
     70_west |
I have an 08 Uly with 8500 miles on it... The clutch is staying engaged refuses to release. The cause is damage from water in the primary case. It was rode about 60 miles with a good 8 ounces or more of water, judging from the fluid level on removal of the clutch inspection cover. The Uly was sitting at a stop sign, in gear, when it lurched forward, stalling the engine. I'm not at all sure as to the extent of the damage, but I think it's likely a minimum of all the plates being replaced if not more. I'm wondering if anybody else has ever had a similar problem and maybe the extent of their damage... also where/who the best online parts and tool vendors might be. Also if anyone knows what types of tools will be required to pull the clutch (Compression tools, etc...) that would be most helpful I've tried two flushes with clean lube, properly adjusted the clutch, all to no avail. Bike pulls just fine with no slippage (had to ride it home in second gear). Primary cover has been removed and no metal or obvious damage is easily seen. Almost forgot, for inquiring minds... An idiot pressure washed the bike, carefully avoiding the wheel bearings, instead concentrated on a smear of grime just above the clutch adj. inspection cover.  Jack | ||
| Treysmagna |
I got lucky. I had water in my primary about a year ago. I changed the oil one day and it was milky and that increased my awareness. I changed it again at my next oil change and again the same problem so I took it to the dealer. They flushed it all out and said they could not find the source of the water and then started questioning me about how and where I had been riding. About six months later I took the bike in for an oil change and new tires. They come to me and tell me that some bearings are bad in my primary and they will have to change them. They did it all under warranty, but they still had the bike a week. I have not noticed any more water in the primary and they never told me what they did to keep it out. I got real lucky! | ||
| Froggy |
Wow I have never heard of water causing this. I have had first hand experience with the frothy primary lube espresso from some water contamination during the winter, but nothing out of the ordinary. | ||
| Thesmaz |
Don't forget that you have to adjust the clutch (inside the primary) as well as the clutch cable. If both of those are adjusted per the sop manual then it may be something wrong with the pilot bearing (I think that's what it is called) and is not letting the clutch plates fully disengage. I put a new clutch in my Uly, not too bad of a job. I got my clutch kit and clutch compressor tool as a kit from ebay. | ||
| Natexlh1000 |
That happened to my 2008 too! The bearing between the inside and outside of the clutch basket went bad due to water. Fixed it under waranty in under a week though. I'm scared to ride the damn thing in the rain now  | ||
| Rotorhead |
I found the grommet for the stator was letting water in on my 06. If the bike is wet and you park it the water puddles against the grommet. BTW no real way to replace just the grommet it's part of the stator assy. Maybe remove the grommet and silicone it and put it back in. | ||
| Crusty |
It has happened twice to my 2008 XT. When I investigated a little more closely, I discovered clear water leaking from the clutch cable, when I had the primary cover off.. Because the boot over the adjuster on the cable sits so close to the exhaust pipe, it becomes brittle and won't keep water out. The water goes through the adjuster, and follows the cable into the primary. I replaced the cable, and covered the adjuster with grease. I also put a zip tie around the top of the boot. Hopefully, that will keep the water out. | ||
| Natexlh1000 |
Ooh. I will try that! Thanks Crusty  I was thinking that perhaps the "formula+" likes water more than the old sports-trans? I never had this issue with my ironhead or X1. | ||
| Dr_greg |
One of the only problems with my now-deceased '06 Uly #044 was the clutch making noise. Turns out the needle bearing was badly corroded due to condensation during my short winter commute. I changed it myself and all was bueno. It never actually affected clutch operation, however, it just made noise. --Doc | ||
| 70_west |
Thanks for the camaraderie... Least it's happened to others (regretfully). My clutch cable is damaged from the exhaust header, and I had ridden all day last weekend from Monteagle to Maryville in the rain. So maybe that's where I picked up some of the water, but I really think it was the "Nut" connecting the seat to the handlebars that did it. Very interesting that the clutch is refusing to disengage though. I wonder if something has come apart and wedged the plates tight maybe. Without a service manual I am relying on good guessing... I've got one ordered and am looking in the morning for a good source for a clutch pack/compression tool. I'm a four season rider, average about 22k a year, and I am having pains having to walk past that beauty every morning to get in a cage! | ||
| Rotorhead |
I know of some primary covers cracking near the clutch adjuster and cuasing some issues. Odie had a great fix for his. http://www.badweatherbikers.com/buell/messages/142 838/483215.html | ||
| Thetable |
Shouldn't an 08 still be under warranty? | ||
| Choyashi |
Maybe it's stolen! He didn't say he owned it! He said he just has it! (Message edited by choyashi on September 12, 2009) | ||
| 70_west |
Thetable, It probably is under warranty, I just wouldn't feel right about taking it in, knowing full well it's not the Manufacturers fault. So I'll eat it since I baked it. I've been searching all morning long for a compression tool, all I can come up with is HD v-twin tools such as this: http://pitposse.com/moproclspcot.html Anybody know if that's the correct tool for the Uly? If not, a link to one would earn you many praises and several atta' boys. | ||
| Gamdh |
American Sport bike has one http://www.americansportbike.com/shoponline/ccp0-p rodshow/5493.html Might want to check with Al to make sure it works with the Uly. | ||
| Dr_greg |
Oh yeah, the compression tool. As I recall, any clutch compression tool that will fit a Sportster will work with the Uly. The one in the Motion Pro pic looks a lot like the one that I have. I vaguely recall getting mine from ironmachine.com, but I'm not sure now. Al would know; if you check with him you're safe. --Doc | ||
| Ft_bstrd |
I sent you a PM. I have a compression tool and would be willing to ship it to you. | ||
| 70_west |
FT that's a fair offer and since I live only a short hop away in Pleasant View, I'd come and pick it up. However I ordered the one from American Sports and specified on the order it was for a Uly. If it happens to not be the correct one I'll give you a shout. I got the clutch to disengage yesterday, by putting the bike in gear, pulling the clutch lever, and bumping the starter. It finally broke free after several attempts. But there is something definitely amiss, a low pitch squealing emanating from the clutch whilst it idled in gear, and it was still pulling slightly. I'll let it sit until I can tear it all down and see what the heck has broken. Probably have done messed around with it too much as it is. Jack | ||
| 70_west |
Well I got the problem located... 'tis bad news, needle bearings are totally shot. The clutch hub and race 'appear' to be okay, but the bearings came out in pieces. They were completely bone dry and well rusted. I don't understand the race appearing to be in good shape, as the shell and inner hub had to be forced apart. So am thinking about just replacing the whole works. Does anybody know if a Sportster clutch assembly will interchange with the Uly ? | ||
| 70_west |
Pictures of the damage... From the looks of it, the clutch had been exposed to moisture for some time.    I replaced the whole clutch with one from an 06 Uly, found on Ebay. 175 bucks tax title and out the door. It was an easy installation and final adjustment as well. So a sad story turns out well in the end and I am back on the road, at least when all this rain ends I will be. Jack | ||
| Dr_greg |
Yup, THAT needle bearing; same as mine. Toldja SO!  I just pressed in a new bearing, much less expensive but I understand your getting a new clutch. Gotta keep the water outta the primary. --Doc | ||
| Pso |
As stated above about teh zip tie, I remember in 06 folks talked about a zip tie on the clutch cable boot because water could and was runing down inside the cable into the primary. that quick fix seemed to have helpd some. (Message edited by pso on September 26, 2009) |
