Forum

[Adam]

A couple of years back I received some excellent advice here regards clutch adjustment and gear changing technique in a thread titled 500 X iffy gear selection. The advice was sound and the result good so thanks again to those involved .............Now,......................Only done about 1.000 miles since and I have a problem with clutch operation, from cold the clutch disengages adequately but once warm it will not release even at full travel of the lever and feels very heavy. I checked cable free play, OK. Went straight to the adjuster in the gearbox end housing and found that with a screwdriver I can rotate the threaded adjuster and lock nut as an assembly but there is no inward or outward movement of the components while turning. I cannot get the lock nut to rotate on the adjuster which suggests to me that some deformation of the threaded rod has taken place. Also found that the washer against which the lock nut sits can be pushed in about 5mm against a spring.......... Any advice as to the cause of the fault would be most welcome as the sun is now shining in Swanage. Does anyone know where I can find a diagram or exploded view of the clutch release mechanism to help me understand the problem a little better? Adam

[Frank]

Presumably you are talking about the Electra X, 5 speed? There is an exploded diagram on this very site in the Parts Book Online - 2005 Electra X-Page 24 - End Cover Assembly - 5 Speed. You should be able to undo the lock nut whilst holding a screwdriver on the adjusting rod and then turn the rod until resistance is felt and then tighten the nut. Is the end of the cable ok and not frayed?

[Adam]

Thanks Frank… Apologies for being so stupid as to not look around the site for the information… My problem is that the threaded adjuster pin just twiddles around and around with no effect at all on the adjustment. It’s as if the pin has become detached from the sleeve (item 3) either by screwing all the way out or by snapping. I’ll take the end cover off on the weekend and see what I can see. Thanks again, Adam.

[Norm]

Adam, just remember when you undo the outer cover you will loose all the oil in the box, sidestand helps a bit

[Craig]

Hello Adam, Like The Others I presume you are Talking about the 5 speed box here....(See Lower down thread:5 Speed Clutch Rod? ..For My Problem)(Clutch Problem)..RE:threaded adjuster and lock nut as an assembly...I Found a Lot of Play in Mine Due To Worn Push Rod & Missing Main Nut on The Clutch since Factory the whole Clutch had Moved (8 years on)...In all Cases The "Threaded Adjuster" Felt too Easy to Turn and Reality it was Pressing on Nowt'... So Not Saying Yours is as Major (or as Simple as it turned Out)..But Best Bet is To Take a Good Look in Both sides..No Major Problems looking in Gear Box Outer Cover or Clutch Cover But as Norm says Beware of Fluid Spills....GOOD LUCK..I Took Photo's as I Did It and fitted upgraded Parts Cable & New Adjuster Nut (550512 Up Graded Clutch Arm Assemb)Which all helped as All had worn a Bit (on a Low Mileage Bike...Cheers Craig..Hope My Ramblings Help a Bit..Its been a Long Day ;0))

[Frank]

Adam, just another tip when removing the cover, relevant especially if you haven't done it before. Once the bolts have been removed I found the cover on mine was stuck fast by the gasket. There are 2 dowels between the cover and the casing which prevent any rotational movement of the cover to break the seal. Tapping it with a rubber mallet is therefore futile and there is little to get a grip on to pull. The cover has to be pulled off straight along the kickstart shaft until it has cleared the dowels, by which time the seal will be broken anyway. There is a raised lip on the top of the cover, it looks as if it was where an external operating arm was considered before a change of mind. If you pass a piece of wood through from the other side of the bike you should get enough purchase on the lip to tap the cover outwards, at least enough to start breaking the seal. The gasket will no doubt be ripped and so a spare, I would say, is essential.

[Adam]

Many thanks for your guidance, guys. Yes it is 5 speed. I found a bit of time today, knocked the outer cover off (thanks Frank) and found the operating lever (to which the cable attaches) has fractured across two of the ‘webs’ between the ball cups. One is a complete fracture and the other is half way across!!! Hitchcocks had an assembly on the shelf and it will be in the post today along with a new gasket. Took the primary cover off and everything seems OK with a visual inspection. Thanks again, Adam.

[Norm]

MrH might have to start bringing these in by the hundred as the older the boxes get the more are going to need replacing. Might need to get a better quality UK made one

[Adam]

I think you’re right, Norm, it’s not the most robust device I’ve ever come across. Certainly explains why turning the screw had no effect on the clutch adjustment, as the fracture widened, the sleeve into which the adjuster screws was able to rotate within it’s location!
Adam.

[Adam]

Big thanks now to 'Mr. H' for getting the parts away so promptly, having rung them Friday lunch time they arrived by Royal Mail on Saturday morning!! Assembled yesterday and all seems well.... Adam