When pulling in the clutch there is a loud squalching noise.
Sounds like your clutch throwout bearing is either bad or going bad. This is due to improper clutch cable adjustment. Just like in a straight shift automobile, if you keep your foot on the clutch pedal, the throwout bearing runs continuously shortening the life of the bearing. On a motorcycle, if the clutch cable is not adjusted to have just a bit of freeplay in it, the bearing will run continously as well shortening the life of the bearing. But, then again it could have just been a faulty bearing.
To repair the problem, you must remove the outer primary cover. First, drain the primary/transmission oil. Then you must loosen the primary chain adjuster beneath the primary cover. Loosen the lock nut and turn the adjuster bolt outward to lower the adjuster shoe inside the primary.
Then remove the clutch inspection cover, the small spring, and the locknut on the clutch release mechansim. Remove the left hand foot peg. Remove all the bolts holding the outer primary cover on. As you remove the primary cover, you will have to turn the screw inside the release mechanism inwards to get it out of the release mechanism.
Once you get the primary cover off, you can see the clutch throwout or release bearing in the center of the clutch assembly. Remove the snap ring and pull the bearing out. Inspect and replace the bearing if found to be defective. Carefully drive the center bolt out and the bearing out of it's holder. Install in the reverse manner.
Reassembly is reverse of disassembly. Install a new gasket on the primary and slide the primary cover in place while turning the clutch release screw into the the release mechanism. Install the bolts that hold the primary cover on and tighten. Tighten small primary cover bolts to 80-110 Inch pounds and the left foot peg bolts to 16-28 Foot pounds.
Adjust the primary chain tensioner to obtain 3/8' to 1/2" up and down slack when checked through upper inspection cover on outer primary. To adjust the clutch cable, find the bellows looking cover over the cable adjuster. Loosen the lock nut and adjust the cable as short as possible. Back at that the adjuster on the primary cover, slowly turn the adjuster screw clockwise until it bottoms out and quits turning. Do not force the screw to turn, just until it bottoms out. Now, back it up 1/4 turn and install the locknut. You may have to turn it just a bit one way or the other to get the locknut in. Install the spring and the cover with the quad ring in place. ADD OIL TO THE PRIMARY, 32 OUNCES of H-D Sport Trans or equilivent. To adjust the cable, adjust cable adjuster in the middle of the cable out as far as it will go without forcing anything. Squeeze the clutch lever a few times and adjust the adjuster so that you have 1/16" to 1/8" freeplay at the lever, about the thickness of a nickle between the lever and lever stancion. Lock the locknut on the cable adjuster and reposition the bellows cover.
As you can see, this is not a very difficult job but it is not for the "faint of heart" since it involves removing the primary cover. I would rate the job difficulty as "moderate" due to this necessity. The only special tool required would be a set of snap ring pliers. Good Luck!
Feb 14, 2010 |
2003 Harley Davidson XLH Sportster 883...