Bonneville America Forums Forums Technical Forums General Tech Clutch experts, help if you can

The shop idiot (me) has done gone did somethin’ wrong. I used the manual and followed BikerThug’s pictured instructions also. I have tried to put install the Barnett clutch and springs. I got it all back together and I have no tension on the clutch lever. Anyone have any ideas? I have taken it back out and checked to make sure I had everything there and put back correctly, it appears to me that I have all parts and they are all where they belong.

may sound stupid but did you check the cluth tension? and also if you did connect the cable? sometimes its the small things that get overlooked

Frank

well I think there was no tension to adjust. But I did connect the cable and had it attached to the cover. I would think there would be some tension without adjustment even with a new cluch if one did not make any changes to that ..... I will check that tomorrow. Thanks Frank. The more ideas the better.

ooooya,

Look at the pic below.


Do you see that yellow arrow? It points toward that little machined plug with a rounded off end (it has a hole or dimple on the end). That little piece is spring-loaded. Did that spring become disengaged? That is the little nub that pushes against the throw-out bearing shaft (with the button-like surface). So, if the spring hooked to it became undone, your clutch would have no tension.

Now look at the next picture.



That little piece with the flat button-like surface in my fingers(in the middle of the throw-out bearing). Well, that piece should slide in and out with total ease (with your fingers). If it doesn't, it is not aligned. Also, make sure all new bolts on that throw-out bearing are tight, and the springs are not crooked.

Also, the big gland nut that you torqued back on to 105nm. Well that nut has one flat side, and the other side has a raised ridge. The side with the raised ridge points outward (so as to accept the little shaft with the button-like surface).

It's a rather simple device. I counsel to just take a deep breath, gather your calmness, go back and approach the assembly methodically, and you'll have no problem.

-BT

BT, thanks for the input. The spring on the machined plug did come loose but I think I got it put back like it should be. I am thinking maybe I put the center nut on backwards (should have been paying more attention with the disassembly) Tonight after work I will give it another try.

One more thought. I had the same issue as you and it ended up I had the big plate that holds the spirngs in, backwards. Make sure it is like BT's picture above (check the markings on the part) or this is exactly what you get. The manual picture is wrong, in mine at least, it took me 3 tries to figure out the book was wrong. jojje has some nice pictures at his site in the technical section under the clutch questions. That's where I got the correct picture to correct mine.

Thanks Pat
I will check that out in just a bit when I get up to the shop. If all goes well, I could be out for a ride tomorrow!! wooooo hooooo. It a son-of-a-gunslinger when one can't ride these machines for a month.

I want to thank Frank, BT and Pat for the input. There were two mistakes I made. The center nut was on backwards that BT talked about and the plate that Pat said to check was backwards also . To any of you that do this, make sure you LOOK at what you are taking off and how it goes back on. These two things just seemed right when they were wrong. It is an easy repair/replacement if you get it right the first time

Great news, now log off, get out there and ride!

Good deal Jack.

For the next time....

When I pull something down and there are parts that are oriented (front/back, up/down, etc.) I take a 2'x2' piece of plywood I keep around and lay them out accordingly. I use a small Cool Whip buckets for screws, bolts, nuts....

I also get out the camera and take pics of things as I tear them down and as they go back together. This has saved my bacon on several occasions!

glad its fixed and no harm done. now go enjoy the thing

Frank

I second the picture taking. Especially with these new fangled digital cams. Good stuff!

My preference is to take pictures and have all the parts laid out for easy reassembly. BUT the “shop” I have to work in is a friend’s basement we have turned into a shop. There is limited room there and usually three bikes, so just not enough room to lay things out on a board or table. As for the pictures, for whatever reason I can not find my camera or I would have taken pictures of the removal of the bent gearchange shaft and replacement. Ended up cutting both ends off that to get it out.

Off Topic...

Hey Ooooya, have you had any problems with moist in your BUBs? See my post in "Exhaust".

Ride Safe!

Bengt
No I have not had that problem. I do not run the packing, just the baffles. I gotta say, I sure wish BUB's had not stopped making the Dresser Dogs (megaphone) pipes for our bikes. My left one got pretty dinged up. But I am thinking about getting them stainless steel color ceramic power-coated. That could be an option to your problem maybe.

Thanks for responding! I''l try the drain hole and will seal the edges with heat resistant paint. I did like the sound with naked baffles, but my better half and her support group voted for the more dampened sound I have now...