Motorcycle Repair: 74 Ironhead clutch, clutch basket, clutch lever


Question
Motorcycle Repair: 74 Ironhead clutch, clutch basket, clutch lever
Pic after rebuild ...
Hi Mike,  This clutch is driving me crazy !!  I brought this bike back from a basket case and the motor runs great now, the bike rides wonderful ... but the clutch just won't get right.   The original bike was electric start only.  Kicker has been added so now we have both.  first issue seemed to be clearance behind the clutch basket and kicker gear ... added a shim and seemed ok.  then clicking noise started ... and figured the clutch pull was now rubbing the top of the nuts on the pressure plate.  little tweak and that has gone away ... but the clutch will not disengage.  have measured the pressure plate clearance to spec and all seems good.  if I start to loosen the PP eventually the clutch will release but then slips when riding ... and seems way out of spec.  New clutch was put in on rebuild.  My thought is that the kicker kit has caused the clutch basket to be out of alignment with the drive gear (front) and so pulling slightly sideways and therefore not releasing?  I'm pulling my hair out  ... and going to take it apart again for the 34th time to see if there's something else I see.  Maybe I should put it on the trailer and come to OH?  any ideas would help.  Dave, Nashville.

Answer
Thy this and see if it will disengage. Loosen the adjuster for the cable all the way, so your making the cable shorter. Loosen the adjuster. Now push the clutch cable inward towards the primary. this will push the clutch lever bact to where its suppose to be. Now adjust he clutch with the adjuster so it just touches and then back out about 1/8 of a turn. Now adjust he cable so you have about 1/8 inch play in the clutch lever
Mike