I have an '85 FXRP and was out riding one day a couple weeks ago when my
drive belt broke. I got the bike home with help from another biker who
was passing by. I went out an got a new belt and started tearing the
bike apart. Took the primary case, rear wheel, and swing arm off. Put
the belt on and started putting the bike back together. I checked the
clutch lever and I could not pull it in. I took the transmission cover
off to check the cable. Took the ball an ramp apart, reset the *****,
put the cable back on the release, and put the cover back on. The
problem I'm having now is, when I squeeze the clutch lever, there is
more free play in the lever then there used to be and the clutch spring
diaphragm does not seem to push out evenly. Its only pushing out on the
one side. The bike has a wet clutch. If someone could point me in the
right direction as to what I'm doing wrong, I'd appreciate it. I have a
service manual but it doesn't seem to help with this issue.

 

Have you adjusted the clutch freeplay on the pressure plate?

 

I didn't adjust the freeplay on the pressure plate. Figured it was fine before I took everything apart. Could the adjustment get out of whack when you take the plate off?

 

It's always a good measure to check/adjust the freeplay after reassembly...Especially now that you have more freeplay at the lever than before disassembly...Also check to make sure the snap-ring in the pressure plate is fully seated inside it's groove.

 

did you check the throwout bearing? Dunno...maybe when the belt snapped something happened there?

 

Good idea! If that throwout bearing/washers are worn it can cause all kinds of problems keeping the freeplay adjustment constant.

 

Was just throwing something random out there. I recently had some clutch issues and a bro was adamant that I check the parts on the other side of the tranny

turned out I had put the wrong size retaining ring in against the release plate so there was no way it was gonna adjust properly. Got the correct circlip in there and everything was cool.

Not sure if a bad throwout would cause a clutch to bind and then stay slack / engage improperly?

 

About 4-years ago I was having problems with the freeplay going loose at low engine speeds and tightening up above 2,500-rpm...I inspected the throwout bearing and found the hole in the center of the bearing was egg-shaped..The bearing was going to fall apart and luckily caught it in time. Replaced the bearing and both washers and haven't adjusted the freeplay since.

I know this is outside the OP but passing on experiences can more than likely come in handy to anyone out there!

 

I pulled the throwout bearing out of the shaft and it seemed fine. It wasn't egg shaped or anything. I noticed that with the clutch lever pulled in and the tranny in 1st gear, I can't spin the tire. Its like the clutch isn't disengaging. Maybe that could help pinpoint a problem. Also, I haven't put any primary case fluid or tranny fluid in the bike yet. Just testing things out before I put new gaskets and fluid in the bike. I have the clutch plates soaking in primary case fluid now.

 

Go back and re-check what you have disassembled...Looks like you induced a new problem during the repair process...The best way to learn is from mistakes...Make sure you don't repeat the same mistake more than once!!!