When I click into gear, stopped, it makes a positive click. Then as I start to let the clutch out the transmission clunks again and it takes off smooth.

Does not always do it, probably about 1/2 the shifts I get a nice positive click into gear and a second one when the clutch begins to disengage.

The bike is a 2007 FXD with 5600 miles on it. I bought it Wednesday of last week with 5300 miles on it. Did it right out of the dealership floor.

5k service was done by the non-dealer but pure Harley shop. My first guess is that the clutch isn't properly adjusted. The clutch does engage pretty quickly off the grip but not enough that I immediately thought that might be the issue.

Any guidance? I am going to do a clutch adjustment. What is procedure (just got the bike, no service manual yet).

Release tension on the cable by loosening the housing all the way. Open the derby cover. Remove the lock nut and spring. Turn the set screw (which direction? Counter Clockwise?) to loosen. Then slowly tighten until I feel resistance, then back out how far (1/8 turn.. 1/4 turn.. 1/2 turn..) I don't remember.

Anyone help me with the details. This will probably be the best place to start troubleshooting because it is the easiest.

Thanks!

 

Check out this video.

http://www.ehow.com/video_2330184_ad...utch-pack.html

You may also need a 11/16" offset wrench.

 

Do the adjustment on a cold engine, an engine with heat in it could throw off the adjustment a little.

 

So I did the clutch adjustment exactly per the video. It seems to be perfectly adjusted.

The clunk is not phased though...

Could a loose primary chain be another cause of this? Still intermittant.

Doesn't clunk often when going from neutral to first at stop.. but slowly releasing the clutch from a down shift where I slow down it clunks almost every time... For example, coming almost to a stop but rolling it. When I go to take off it clunks almost every time.

Anymore ideas?

-Mike

 

I went to the shop I bought the bike from. They said everyone's bike does this... Can anyone else confirm?

I call BS. I was a service writer at two dealerships, this is my 5th Harley (first 6-speed). He said Harley put out a service bulletin to just hit the throttle hard to get the primary chain adjuster to click another spot tighter. He did it and nothing, same issues.

Any one else have this issue? Heard of this? Anything?

 

I have the same exact issue. I've never been able to determine the cause. I've adjusted my clutch a thousand times and I know it's adjusted properly. Wish I could offer more help but I haven't been able to determine what's going on either.

 

Have you contacted any service departments or anything. I got another response saying there is some sort of safety mechanism in the transmission and when a bolt from it comes loose this noise starts. Tighten it back up and it's gone, trying to get more info on what bolt they are referring too.

I also contacted a dealer via e-mail and will call tomorrow to see what they say.

 

No I haven't taken it in to the service department. I'm really not willing to pay them hours in labor to troubleshoot the issue. It's been happening forever to no ill effect that I can tell (doesn't mean my **** isn't about to blow up though).

 

It just bugs the HELL out of me... I'm willing to pay them to figure out what it is exactly. Assuming I don't have to enter the transmission, I'll be taking care of the rest.

 

Well if you end up figuring it out please post back and I'll do the same if I stumble on the cause.