 Clutch issues
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Joined: Jan 2008
Posts: 199
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OP
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Joined: Jan 2008
Posts: 199 |
I have an '03 BA with a 790 that just rolled 26,000 miles. Last night I noticed that I had the clutch lever damn near all the way out before anything would engage. No biggie. Simple adjustment fixed that..... No so quick.... Now I notice that when I roll on the throttle with any authority, it slips. The revs go high and the speedo stays where she is. My guess is the clutch or springs are going. Anyone have any ideas on this??
2003 TBA Thunderbike pipes / floorboards / and the most uncomfortable seat known to man....
Barry aka: 8-Ball
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
I fixed mine with new H.D. springs, but your symptoms sound like you may need both plates and springs. It's a straight forward and easy job. Don't forget to order a case cover gasket too.
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Re: Clutch issues
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Joined: Apr 2008
Posts: 3,937
Loquacious
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Loquacious
Joined: Apr 2008
Posts: 3,937 |
I'd say 1.) IF you just adjusted the clutch action 2.) it just started slipping under load You need to re-check your work. (I did) 
And you may see me tonight
With an illegal smile
J. Prine
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Re: Clutch issues
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Joined: Apr 2007
Posts: 3,053 Likes: 6
Loquacious
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Loquacious
Joined: Apr 2007
Posts: 3,053 Likes: 6 |
Quote:
I'd say
1.) IF you just adjusted the clutch action
2.) it just started slipping under load
You need to re-check your work.
(I did)
+1
12 Rocket Roadster
03 Bonneville America
69 BSA Firebird Scrambler
73 Yamaha TX 750
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
When your clutch engages at all the way out, the causes can be 1.) cable stretch 2.) Plate wear 3.) Adjustment 4.)Fatigued springs 5.) Combo of previous four My personal experience, when the clutch engages at the end of the let off, it's time to rehab that sucker. Adjustment? Which direction do you go? Tighten the cable, no, more slippage, loosen, the clutch still engages where it does now. So, explain it to me and I'll eat a Crow dinner and send you some pictures. 
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Re: Clutch issues
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Joined: Mar 2009
Posts: 12,964
Stickman Yogi
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Stickman Yogi
Joined: Mar 2009
Posts: 12,964 |
It's a bit early for the clutch to be going... my '03 has around 50,000 miles with no clutch issues. Here's hoping it's just an adjustment issue.
Live to love, love to live.
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Re: Clutch issues
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Joined: Jan 2007
Posts: 331
Adjunct
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Adjunct
Joined: Jan 2007
Posts: 331 |
I agree with Rob and Greg. Unless you are a burnout king your clutch should last a lot longer than 26,000m. Sold my o3 at 80,000k and oem clutch working perfectly.  
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Re: Clutch issues
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Joined: Jul 2007
Posts: 6,060 Likes: 6
Worn Saddle
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Worn Saddle
Joined: Jul 2007
Posts: 6,060 Likes: 6 |
Quote:
It's a bit early for the clutch to be going... my '03 has around 50,000 miles with no clutch issues. Here's hoping it's just an adjustment issue.
Mine too. I'm hoping for you that you just made a mistake adjusting the cable.
Fidelis et Fortis
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Re: Clutch issues
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Joined: Jan 2008
Posts: 199
Adjunct
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OP
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Joined: Jan 2008
Posts: 199 |
I'm hoping I made a mistake too!!! That's a much easier fix. I'm a conservative rider and I'm not heavy on the throttle. I would hope the clutch would last a little longer than 26K. I'll play with the adjustment and report back.
2003 TBA Thunderbike pipes / floorboards / and the most uncomfortable seat known to man....
Barry aka: 8-Ball
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
You should be able to pull the clutch lever back a approx. 1/4" before any cable take up happens, if that's what you have now and the actual full engagement is still the same. At the very least, your C. springs have taken a set and need to changout. Here's to hoping I'm wrong, I don't get a thrill at others misery and misfortune. But I have changed 3 sets of springs on three bikes with 28K on the highest miler. Fast Eddy sells them (spring sets) at as good a price as I could find.
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Re: Clutch issues
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Joined: Jan 2008
Posts: 1,152 Likes: 12
Learned Hand
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Learned Hand
Joined: Jan 2008
Posts: 1,152 Likes: 12 |
Quote:
I'm hoping I made a mistake too!!! That's a much easier fix. I'm a conservative rider and I'm not heavy on the throttle..
Barry I have ridden with you and that statement conflicts with my observations. 
IMHO the stock clutch springs are pretty light. I swapped mine out for Barnetts heavy duty springs at about 15k miles. Much better. Didn't cost much. If you time it with an oil change, even better.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: Clutch issues
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Joined: Jan 2008
Posts: 199
Adjunct
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OP
Adjunct
Joined: Jan 2008
Posts: 199 |
Quote:
Barry I have ridden with you and that statement conflicts with my observations.
Gee.. Thanks.. 
I'm not THAT bad, am I?? I can barely keep up with Roadworthy. And I don't get pulled over like Justin!!!
2003 TBA Thunderbike pipes / floorboards / and the most uncomfortable seat known to man....
Barry aka: 8-Ball
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Re: Clutch issues
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Joined: Aug 2007
Posts: 10,707 Likes: 3
Should be Riding
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Should be Riding
Joined: Aug 2007
Posts: 10,707 Likes: 3 |
Quote:
I'm not THAT bad, am I?? I could never ever keep up with Roadworthy.
There, I fixed that for you
I wish I could help you on the technical side, all I can tell you is that when my clutch started slipping, I could hammer the throttle and it would rev up without accelerating. That was with the red Barnett springs, which are 90 pound I think. Very stiff. I changed my clutch plates and all was well after that. My stock clutch plates were scorched black.
Always remember to be yourself. Unless you suck. Then pretend to be someone else.
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Re: Clutch issues
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Joined: Jan 2008
Posts: 199
Adjunct
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OP
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Joined: Jan 2008
Posts: 199 |
Ha!! Nice re-quote, Dave. I'm thinking I'm going to need both plates and springs. Hopefully it won't be too bad of a job to do.
Other than the plates, springs and gasket, what else am I going to need to replace ??
Last edited by sbs287; 09/20/2013 1:08 AM.
2003 TBA Thunderbike pipes / floorboards / and the most uncomfortable seat known to man....
Barry aka: 8-Ball
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
Locate and secure the wavy washer as soon as you crack the case and do not forget to replace it, when you go back together. Oil and filter too, your old oil is full of what's missing from your clutch plates. Ascertaining your torque specs ahead of time helps. If you got your ducks in a row, the whole job takes less than two hours.
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Re: Clutch issues
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Joined: Apr 2007
Posts: 3,053 Likes: 6
Loquacious
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Loquacious
Joined: Apr 2007
Posts: 3,053 Likes: 6 |
Good reminder Ryk on the starter issues. Make sure all the starter drive parts are properly in place before you reassemble especially that wavy washer on the starter idler gear. Some fellows have literally cracked their engine housing around the idler boss supports.
12 Rocket Roadster
03 Bonneville America
69 BSA Firebird Scrambler
73 Yamaha TX 750
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Re: Clutch issues
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Joined: Jan 2008
Posts: 199
Adjunct
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OP
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Posts: 199 |
Okay, since my mechanical experience consists of filling that red metal thingee in front of my seat with gas, I'm going to need a complete list of everything I need before tackling this job. I know I'll need springs, plates and the gasket. What's this wavy washer thing you're talking about.... And other than an oil change, what else will I need??
2003 TBA Thunderbike pipes / floorboards / and the most uncomfortable seat known to man....
Barry aka: 8-Ball
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Re: Clutch issues
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Joined: Apr 2008
Posts: 3,937
Loquacious
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Loquacious
Joined: Apr 2008
Posts: 3,937 |
Quote:
Okay, since my mechanical experience consists of filling that red metal thingee in front of my seat with gas...what else will I need??
A good mechanic.
And you may see me tonight
With an illegal smile
J. Prine
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
#1 A friend that has been there and done that.
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Re: Clutch issues
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Joined: Jan 2008
Posts: 1,152 Likes: 12
Learned Hand
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Learned Hand
Joined: Jan 2008
Posts: 1,152 Likes: 12 |
Do you have the Hayes service manual? If not get one, it will walk you thru it. It's a fairly straight forward job. Good way to waste an afternoon instead of riding.
05 speedmaster - 1100cc, 11:1 racing pistons, Carillo rods, thunderbike cams, ported and polished head, 2mm over intake and exhaust valves, Barnett kevlar clutch, scepter pipes, oversize manifolds, 45mm HSR's, TTP stage 4 firestarter
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Re: Clutch issues
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Joined: May 2010
Posts: 5,720
Check Pants
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Check Pants
Joined: May 2010
Posts: 5,720 |
Quote:
Do you have the Hayes service manual? If not get one, it will walk you thru it. It's a fairly straight forward job. Good way to waste an afternoon instead of riding.
The money you save doing it yourself, will pay for the book and give you change.
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Re: Clutch issues
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Joined: Jan 2005
Posts: 11,122 Likes: 11
Should be Riding
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Should be Riding
Joined: Jan 2005
Posts: 11,122 Likes: 11 |
Blowing gravel off rural roads
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