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  #1 (permalink)  
Old 09-30-2017, 07:00 AM
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Location: Flemington, nj
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Unhappy 2005 Big Dog Chopper Clutch problem

Here is the history,
I was riding my bike and I shifted into like 3rd gear while going down the highway and all of a sudden my clutch lever went slack and the clutch is not engaged....no tension in lever at all like as if the cable broke. I had to pull over .. could do nothing so I had to get towed home. Got it home did some research and took off the push rod assembly after collapsing my clutch cable even tho there is no tension in it anyway. pulled off the ball ramp assy and the push rod is completely out. I move my shifter through gears but nothing engages like the clutch is stuck open. Does anyone have any clue what could be the problem? I feel that the ball ramp assy isn't the issue because with it out of the bike it still wont engage into any gear. I can move the shifter through gears or so it feels but nothing is engaging to keep my bike from rolling as if the clutch is being held in. Any help on this would be greatly appreciated. I just want to fix it if it isn't something major because I do not know of any shops in my area that work on big dog choppers. I am in Flemington NJ. Thanks in advance

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  #2 (permalink)  
Old 09-30-2017, 02:10 PM
STEINBVG's Avatar
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Bike Year, Make, Engine: 2010-14; MYSELF; 96",113",120",127"
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While bike is parked and off you should be able to shift back and forth regardless of clutch. And once in a gear- the bike should not be able to roll.

Take off the top cover of the trany and see how the shift fork and the cam move the gears around. There might be your 1t problem.

Then work on what happened to the clutch which apparently went bad. What I do when install the ramp and push rod, I use the screwdriver and push against the push rod from the left side( the adjustment bolt out) and ensure smoth movement of the ramp observing the clutch lever go home.
Then I press lever- and feel the push rod moves my screw driver out. Go back and forth like that.
There should be no resistance in this exercise. After that I screw in the adjustment bolt, touch it down and back off 1/4 turn and tighten the nut.
After that I adjust the cable leaving a tiny slack.

Even though it,s unlikely to have 2 problems at once, but not impossible.
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Last edited by STEINBVG; 09-30-2017 at 03:29 PM..
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  #3 (permalink)  
Old 09-30-2017, 03:03 PM
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Seems like it would be easier to just pull the clutch, to see if something is jammed maybe, from your description.....Mine only takes about 20 minutes..you would be able to view the push rod action....or problem....open or closed primary?
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