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Chingo3000
Posted on Monday, July 04, 2011 - 05:54 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If it's not one thing, it's another. First I lose my dipstick, thanks Brother in Buells, my oil level is good now. I hop on today to give my cork plug a trial run and now I have another problem. I pull the clutch but it doesn't fully disengage! I had no problem with this until I parked for 2 days. It's been parked in the hot Georgia sun, but I doubt that would effect operation to this extent. Any suggestions? I need to hit the road 300 miles back home in 12 hours.
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Chingo3000
Posted on Monday, July 04, 2011 - 06:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I checked the primary and it's filled to the proper level. I played around with the clutch adjustment, tightened and loosened even abit over-exaggerated both ways. The clutch motion just will not disengage. With the clutch inspection cover open, it's obvious the cable isn't broke. What else can I do? I don't remember the primary chain tightness specs but it seems to be within the limits of when I've checked at service time.
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Mtnmason
Posted on Monday, July 04, 2011 - 06:50 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

any chance the clutch cable is stretched but still operates somewhat? Happened to me on my yamaha
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Chingo3000
Posted on Monday, July 04, 2011 - 07:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

While researching with my phone, I also adjusted the screw under clutch cover; if I'm correct this is the ramp adjustment? Tighten until it bottoms out, back off and re-tighten until a little resistance is felt... Please correct me if I'm wrong. Then I readjusted the clutch cable as well to between 1/16 & 1/8 between the lever assembly and cable housing. Am I missing something here or not doing something correctly? I should be drinking beer and having a good time instead of pissed off in a hotel parking lot.
Mtnmason - the cable being stretched could always be a possibility I guess. Working the lever with the clutch cover off shows that there is definitely movement. Then with what I understand to be a proper adjustment, I think I could rule that out. Then again, I am in a parking lot with limited resources. Anything is possible.
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Brumbear
Posted on Monday, July 04, 2011 - 10:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

crack the nut loose tighten screw till you hit resistance back off 1/4 turn hold in position lock the nut is how I used to do it
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Sifo
Posted on Monday, July 04, 2011 - 10:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The clutch ramp adjustment should be turned in until it "lightly bottoms" then backed off 1/4 turn. Back it off slightly more as necessary to get the locking nut/spring in place. I don't see how this could have changed just sitting in the sun though.

Yours almost sounds like the symptoms of when the lip on the primary cover is failing.
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Glitch
Posted on Tuesday, July 05, 2011 - 07:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Check the cable end at the clutch lever, if the cable is getting longer, it's probable because it's about to break.
They break one thread at a time, and you get the symptoms you've described.
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Chingo3000
Posted on Tuesday, July 05, 2011 - 02:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

got myself home today. won't see my bike until next monday though. i do have a service manual. i'll make sure to check the cable to make sure it's not in the process of breaking. should i have to open the primary, any suggestion or tips? Or just read the manual?
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Sifo
Posted on Tuesday, July 05, 2011 - 04:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Clutch cables will usually break right at the lever. If the ferrule at the end of the cable isn't lubed once in a while it stops rotating in the lever and forces the cable to bend sharply leading to failure. I'm not sure that it's the cable though just because of the fact that you set the free play at the lever and had the same problem. That should have been a temporary fix at least. It's all fairly simple mechanical stuff that you should be able to figure out with a careful inspection.
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Fast1075
Posted on Wednesday, July 06, 2011 - 07:17 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If the cable is ok...check the lip on the primary cover.
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Brother_in_buells
Posted on Wednesday, July 06, 2011 - 03:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Chingo3000 ,we are here to learn some good tips and tricks and also help each other when we can
to have full enjoyment of Mr Buell's motorcycles!

And maybe your problem is the same as the buellers in this thread!?
http://www.badweatherbikers.com/buell/messages/406 2/635607.html?1309265111
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