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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » 2009 Ulysses clutch problem « Previous Next »

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Pawdaddy
Posted on Tuesday, August 26, 2014 - 07:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

New problem. Worked thru the ECM relocation, replaced voltage regulator due to low voltage code. Just now getting to enjoy her and going to work one day, no clutch. That was a spooky ride till I stopped. Clutch lever had alot of slack like something broke. Clutch cable attached at lever, and upon removing inspection plate cable is attached inside case at the adjustment screw. Hmmmm maybe just needs adjustment. Read up in the manual and set cable as the book said. First time when starting the bike to check clutch when pulling clutch in you could feel vibration in the lever. Backed up and followed procedure again. This time when starting bike the clutch lever moved. I'm at a lose help
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Mrakz83
Posted on Tuesday, August 26, 2014 - 09:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Looks like you will have to take the clutch cover off and make sure that the cable end is still attached. Luckily, it's not hard to remove. I think you'll have to prop the bike up without use of the kickstand, though. If the cable is not broken and still attached, you'll have to get the clutch apart to see what else might be wrong. How many miles on the bike? Has the clutch been through hard use? When you pull the clutch lever in and out, does the end inside the clutch cover move in and out?

(Message edited by MrakZ83 on August 26, 2014)
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Pawdaddy
Posted on Wednesday, August 27, 2014 - 06:05 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bike only has 13,000 miles. No hard life. When pulling the clutch lever the cable does move all the way to the adjusting screw area behind the inspection cover plate. Like I said I did the adjusting procedure the way the manual says. Must be time to pull the case and dig deeper.
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Gabby_duck
Posted on Thursday, August 28, 2014 - 07:48 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Had a similar problem on my 06 uly.I had failed to follow the written instructions.2nd attempt was all good.
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Pawdaddy
Posted on Monday, October 13, 2014 - 09:39 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Turns out the problem was another inferior part on my Ulysses. The lip on the primary cover in the ramp area broke. Seems from my research this is a common problem. Harley Davidson should be liable for this problem. I believe a recall should have been made, for this is a safety issue. Nothing like being on a on ramp running thru the gears to merge into traffic and you loose the clutch after reaching 3rd gear. Buell owners beware of this problem.
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Buellistic
Posted on Monday, October 13, 2014 - 10:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you adjust the PRIMARY CHAIN "TOO TIGHT"(FSM is wrong)you will have CLUTCH PROBLEMS, SHIFTING PROBLEMS, TRANSMISSION PROBLEMS, and CHAIN ADJUSTER PROBLEMS ...

PRIMARY CHAIN ADJUSTMENT Class 101 and CLUTCH ADJUSTMENT Class 101, just PM me for copy's ...
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Froggy
Posted on Monday, October 13, 2014 - 10:56 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The lip on the cover only breaks if the clutch cable is over tightened when installed.
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Buellistic
Posted on Monday, October 13, 2014 - 11:21 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

"RIGHT ON !!!". Foggy !!!
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Court
Posted on Monday, October 13, 2014 - 06:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Paw daddy

Tell me about your research.

Did you employ a statistally significant sample?

We're there any cases of failure among bikes with properly adjusted tensions?
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Gabby_duck
Posted on Wednesday, October 15, 2014 - 05:07 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

http://www.badweatherbikers.com/buell/messages/384 2/282980.html
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Gabby_duck
Posted on Wednesday, October 15, 2014 - 05:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

This issue is one I haven't heard of before.Buellistic or Froggy do you guys know of this issue and what can cause or prevent it.
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Pawdaddy
Posted on Saturday, October 18, 2014 - 07:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I had never adjusted the clutch cable prior to my clutch issues. It seems to be enough of a problem that a gentleman in New York has made a fix for this problem. The people at American Sport Bike in California also confirmed that this was a common problem. I hadn't noticed the broken Primary cover and I was about to purchase tools from American Sport Bike to dig into the clutch area and find the problem. Only then did American Sport Bike tell me about the Primary cover issues and I checked the cover and sure enough it was broken. Ill get her fixed and motor on down the road.
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Pawdaddy
Posted on Monday, October 05, 2015 - 01:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

More data on this issue..
Buell Forum Fix for the Primary Cover
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Pawdaddy
Posted on Monday, October 05, 2015 - 01:39 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Click on this link for more info on this issue...http://www.buellxb.com/forum/showthread.php?42555- Fix-for-the-Primary-Cover
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