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Buell Forum » Big, Bad & Dirty (Buell XB12X Ulysses Adventure Board) » BB&D Archives » Archive through April 01, 2014 » Clutch Return Spring broken? « Previous Next »

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Deeds
Posted on Thursday, March 06, 2014 - 07:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Seems my new Uly is cursed. I was adjusting the clutch today, following this video guide (below). It seems I might have overtightened it, because when I went to pull on the lever, I heard a sound of either something snapping, or coming undone. Now there is zero tension at the clutch lever. Looking back under the adjuster screw under the clutch inspection cover and there is no tension where the cable hooks up, the the adjuster screw spins much more freely than before. Taking it to a shop tomorrow for them to have at it. Any ideas?

I have verified that the cable is NOT broken.

https://www.youtube.com/watch?v=UpMnccIMSIs&t=101

(Message edited by Deeds on March 06, 2014)
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Griffmeister
Posted on Thursday, March 06, 2014 - 10:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Don't know if this is even possible, but could the actuator "cam over"? If you follow that video, at 2.25 the lever you're looking at would have to have been pulled way forward of this position leaving the cable slack. You can at least pull the inspection cover back off to confirm this.
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Sagehawk
Posted on Thursday, March 06, 2014 - 10:51 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Might check the shoulder that the release mechanism rides against in the cover. Some have had that crack and break out. Turns messy after that but fixes have been documented here.
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Reepicheep
Posted on Friday, March 07, 2014 - 08:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That video gives misleading info... You should have followed your manual.

It says "turn the screw until it stops then back off one quarter turn". That's wrong. It should say "turn the screw until it lightly bottoms and back off one quarter turn".

Buy the service manual... Heck, I think those instructions might even be in the owners manual.

Did you turn the screw snug, or did you lightly bottom it?
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Prior
Posted on Friday, March 07, 2014 - 08:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Might check the shoulder that the release mechanism rides against in the cover. Some have had that crack and break out. Turns messy after that but fixes have been documented here.

I'd bet this is the case. I had a 'dealership' replace a stator on my Firebolt under warranty that overtightened the clutch mechanism when the clutch cover was reinstalled. Mine popped in the parking lot at the dealership and they wouldn't repair it. Exact same symptoms as what you are stating.

Back the adjustment screw out, pull the ramp mechanism out and take a look at the flange where it rides- I suspect you'll see a fracture.

Prior
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Djohnk
Posted on Friday, March 07, 2014 - 09:51 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I hope it's this (that's what it was in my case):
It says "turn the screw until it stops then back off one quarter turn". That's wrong. It should say "turn the screw until it lightly bottoms and back off one quarter turn".

and not this:
Back the adjustment screw out, pull the ramp mechanism out and take a look at the flange where it rides- I suspect you'll see a fracture.
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Reepicheep
Posted on Friday, March 07, 2014 - 10:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hopefully it isn't both. Not a disaster, as it isn't hard or stupid expensive to get a new primary cover.

But it isn't free or quick either...
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Prior
Posted on Friday, March 07, 2014 - 11:46 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It's not. When mine popped, I had a new cover hand delivered by DaveS the next day. The 'dealership' that broke the thing took a few weeks to get it back in stock!

Keep us updated on the results!
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Teeps
Posted on Friday, March 07, 2014 - 11:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sounds like the primary cover broke.

http://www.badweatherbikers.com/buell/messages/384 2/282980.html

If so, (and I hope it's not) that's going to leave a mark in your wallet.
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Dirt
Posted on Friday, March 07, 2014 - 04:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Deeds,

If it turns out it's your primary cover, PM me. I have a spare one.
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Timbobuell
Posted on Friday, March 07, 2014 - 06:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

try doing the full clutch cable adjustment again. Had the same type experience while starting with bike in gear and clutch lever pulled in. I will never do that again. neutral starts only for me. Sounded very bad, but after full adjustment all has been good. It was like the spring/nut had jumped its track. Worth a try, worked for me.
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Deeds
Posted on Thursday, March 13, 2014 - 06:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Got a call today from the shop. Yes, the primary cover is busted. Dirt, I've sent you a pm.
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Zac4mac
Posted on Sunday, March 16, 2014 - 11:56 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That happened to me on my 03 Firebolt.
I had a very old aircraft machinist weld it up.
He beefed it up a little too.

That was in 05, still good.

Zack
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