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  #1 (permalink)  
Old 10-25-2017, 04:35 PM
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Bike Year, Make, Engine: 2007, T/C 88 Custom
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Ultima clutch help

put a new clutch pully , clutch hub and discs on my 3.35 open primary.
straightforward remove and replace. now my clutch lever is almost all the way in and rock hard. ball and ramp was never touched did not change clutch cable adj. or clutch plate adjustment. should have been no issues.
went in and checked ball/ramp and can move clutch lever by moving ramp by hand.
pulled new clutch pulley off and reinstalled old one...same problem.
played with clutch adjust bolt at clutch plate and got no change...no tention on lever and no movement on presure plate.
relaced unit due to age/wear, older version without the steel inserts the new ones have.

any thoughts?
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  #2 (permalink)  
Old 10-25-2017, 04:50 PM
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Quote:
Originally Posted by rem hamilton View Post
put a new clutch pully , clutch hub and discs on my 3.35 open primary.
straightforward remove and replace. now my clutch lever is almost all the way in and rock hard. ball and ramp was never touched did not change clutch cable adj. or clutch plate adjustment. should have been no issues.
went in and checked ball/ramp and can move clutch lever by moving ramp by hand.
pulled new clutch pulley off and reinstalled old one...same problem.
played with clutch adjust bolt at clutch plate and got no change...no tention on lever and no movement on presure plate.
relaced unit due to age/wear, older version without the steel inserts the new ones have.

any thoughts?
You would be surprised that when installing the right side cover/ ramp back something might move and get stuck very easily.

What I do is use a screw driver pushing against the push rod from the left side observing the clutch lever go home, then I engage the lever feeling that the push rod moves my screwdriver out and do that a few times back and forth. I wanna see and feel good consistently smooth throw of the push rod/ rump complex.
Granted, when you had the cover off and checked the ramp exposed -it,s capable to move full range in the first place, without any kinks.

When I verified it is good, then I install the adjustment screw in.
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  #3 (permalink)  
Old 10-25-2017, 06:30 PM
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thanks steinbvg will give it a try. still don,t get what the problem is. should have been straightforward change out.
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Old 10-26-2017, 03:02 PM
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Quote:
Originally Posted by rem hamilton View Post
thanks steinbvg will give it a try. still don,t get what the problem is. should have been straightforward change out.
Yep ramp and ball..I have to take the cover off and redo ramp and ball.
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Old 10-26-2017, 04:34 PM
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I have seen a slight bur on the mainshaft restrict the clutch from going all the way on and seating against the bearing in the primary. I would start there. It would allow you to get a torque on the clutch with it not in its original position and the extra space could be causing the clutch to adjust differently....
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  #6 (permalink)  
Old 10-29-2017, 04:56 PM
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thanks for all the imput. checked everything and the problem had to be at the ramp. found the outer ramp had slipped and the arm was too far forward. must have happened when the clutch pulley was removed and all tention came off the ramp. probably hit the clutch lever while working on it. removed the clip ring, repositioned the outer ramp and all is good.

the new ultima pully came with metal inserts. night and day difference in performance. sound when clutch pulled in is gone. so good to have my bike back on the road.
(if you see my pictures last winters project was to powder coat bike black).
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Old 10-29-2017, 05:11 PM
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Quote:
Originally Posted by rem hamilton View Post
thanks for all the imput. checked everything and the problem had to be at the ramp. found the outer ramp had slipped and the arm was too far forward. must have happened when the clutch pulley was removed and all tention came off the ramp. probably hit the clutch lever while working on it. removed the clip ring, repositioned the outer ramp and all is good.

the new ultima pully came with metal inserts. night and day difference in performance. sound when clutch pulled in is gone. so good to have my bike back on the road.
(if you see my pictures last winters project was to powder coat bike black).
Here you go. Yep, those ramps are very temperamental and get stuck. Glad it worked out.
__________________
VITALY.
SORRY FOR THE UPPER CASE. I AIN'T YELLING. I JUST MAKE TOO MANY TYPOS IN THE LOWER.

113"s&s, Walz softail 2000/2012 prostreet
96"s&s, Daytec dyna/ softail hybrid, 2010 chopper
127"Ultima, Chassis Design rigid 2013 bobber
120"Ultima, Kraft Tech rigid 2014 bobber
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