clutch issues

i have an '80 1000ltd, i was riding the other day and all of a sudden my clutch became full of slack. On the road i adjusted it out as far as i could to get home, it still had over 1/2 lever of slack.

I took and cleaned/lubed the cable and the pushrod, while it seemed to help some, i still have way too much slack. I know it is not in the cable or connecting assembly, because it works fine by hand.

The clutch still works, as far as i can tell its not slipping. It almost seems to me as if the pushrod isnt coming out far enough. Anyone have any ideas what to look for when i take it apart?

Nevermind, issue solved--- the nut on the clutch adjuster on the sprocket cover came loose...

haha, mine did that 3 days ago too...check the adjuster in the middle of the cable too, mine was loose there as well

My husband is having the same problem with his 76' 900. he has adjusted at the lever and at tightened the nut on the sproket which was loose. He is still having problems. Thosse two things helped a little but it is still not engaging right away when he goes to start out. He will try adjusting it in the middle of the cable and see if this helps further. Are there any other ideas? Is it possible the clutch is going bad? Right now this is his only means of transportation to and from work every day and he has to drive 40 miles round trip. He needs to know he will get there and back. Both of our other cars left him sit last week and we don't have the money to repair them at this time so he needs a great running bike to get him to work. We need this little problem taken care of ASAP. Thanks.

wifeofaKZlover wrote:

My husband is having the same problem with his 76' 900. he has adjusted at the lever and at tightened the nut on the sproket which was loose. He is still having problems. Thosse two things helped a little but it is still not engaging right away when he goes to start out. He will try adjusting it in the middle of the cable and see if this helps further. Are there any other ideas? Is it possible the clutch is going bad? Right now this is his only means of transportation to and from work every day and he has to drive 40 miles round trip. He needs to know he will get there and back. Both of our other cars left him sit last week and we don't have the money to repair them at this time so he needs a great running bike to get him to work. We need this little problem taken care of ASAP. Thanks.

Tightening that nut won't solve the problem, he needs to turn the center adjuster screw IN until he feels resistance. Hold the screw with the screwdriver and snug down the nut with a wrench.

Here's the ROUTINE clutch pushrod adjustment.

FIRST-- adjust the pushrod gap:
With ample slack in cable;
Hold clutch pushrod adjuster screw in place with screwdriver;
Loosen the locknut;
Turn screw counterclockwise backing it out and loosening it up;
Turn screw clockwise back in until feeling it seat against end of the pushrod;
Turn screw counterclockwise back out 1/2 turn (which allows small gap between end of screw and pushrod);
Hold screw in position with screwdriver;
Tighten the locknut;
At this point, the slight gap between adjustment screw and end of pushrod has been set and locked in position.

SECOND-- adjust the cable slack:
Now, reduce cable slack using the inline adjuster near exhaust header and the adjuster at handlebar, until there's a little slack in the cable when the clutch lever isn't being squeezed.

Good Luck!