push rod end
Been riding fine when I had a sudden issue with the clutch. It made a "clunk" sound when I changed dow from 5th to 4th. When I went to change back up agin the "clunk" and had no clutch at all. Thought it was the cable at first but that was fine.... got into the transmission and found that the finger that activates the push rod for the clutch operated by the release lever had sheared in 2. It's a 1986 FLST so it's getting on but a substantial bit of metal I'm surprised it failed like that. Couldn't see anything else wrong and the clutch had been feeling good before it happened. Waiting for the part but want to check if anyone knows what the distance of travel for the pushrod end should be? I guess there will not be an exact measurement as it will depend on the state of the clutch but I figured if it wasn't enough the lever could forced the finger and busted it?
The photo shows where it is sitting at the moment, I have net done anything to clutch side so it will be as it was when it broke.

 

Not exactly familiar with the earlier 5 speeds. I have a 98 and the amount of travel I had on my 5 speed was approximately .070" measured with a dial indicator at the clutch release plate. You can access it through the clutch derby cover on the primary side...

 

Make sure that throwout bearing is good. Can't say I have ever seen the finger break but it is a cast piece, time and pressure. I would post this in the shovelhead section and see what those guys say. that style of clutch release was used in the older bikes. In fact, 86 was the last year for it.

 

Hi Mark thanks for that... I wasn't sure where best to post it first off. I've got the bits I'm going to reassemble and see what it looks like...... might be back!!
G

 

The Moonraker is my 1985 FXRS that I purchased brand new 34 yrs ago. Same "Clutch release finger" setup. I've had 2 break over that time...in 290,000 mi.
Little if any warning...they just break. I'm a big "While-I'm-in-there" guy. With as many miles as I have on my bike, I'll go ahead and replace anything I can easily access "While I'm in there".
In this case, I go ahead and replace the throwout bearing and right-side push rod end.
After you put it back together...MAKE SURE you have the recommended 1/8" of free play in your clutch handle. If you adjust it to the point that all the "slop" is out and it's nice and snug...you'll be back in there replacing the throwout bearing and pushrod end in no time.

 

Hey
Thanks for that.... I have put it all back together and adjusted everything as the spec in the book.... seems to be working fine although now you mention it I wish I had changed the release bearing while i was in there... well its done now and it looked pretty good anyway. My bike has only done 63000 but I do have a lot of town work to do so a lot of clutch usage.
Safe riding....