Replaced the gasket on the clutch release cover today. There aren't specific instruction in the service manual for replacing the gasket.

I just popped the cover off enough to get to the gasket and put the new one on. Should I have made sure anything was aligned or should it have been that simple. The reason I ask is I can't get all the free play out of the clutch cable doing the clutch cable adjustment now, I'm a bit more then 1/8" gap and pretty well down to the end of the screw.

 

sounds like it's time to dig into your derby cover to check tolerances in there.

 

Please read the link, starting with the second post. I think that's what happened here.

https://www.hdforums.com/forum/touri...ctuation+cover

 

Is it possible to even flip them without fully removing the cover? I didn't even pull the cable off the cover or the exhaust. I was able to get all the bolts out to allow me to tilt the cover back enough to get the old gasket out and put the new one on.

 

If you didn't pull the lever accidently when the cover was loose, the ramp lever should have stayed at 12:00. But your problem occurred after you pulled the cover which is why I suggest that.

Have you readjusted the clutch since?

 

Yeah, I readjusted the clutch after I put this back on which is when I noticed the cable freeplay problem.

BTW, I'm able to pull the clutch in and change gears (though going into 1st from neutral seems to be louder then it was. Haven't test rode it yet, is raining. Also, if I have to pull the cover again am I able to reuse the tranny oil? I out new in today when I did the gasket replace and no place around here to get the red line oil.

Thanks Stiggy!

 

Put the bike wheels up on 2x lumber and lean way over to the left on the jiff stand. Don't have to drain tranny oil, will only lose a minute amount.

 

Wanted to follow up on this.

I let it sit overnight and went back out and tackled it again fresh. I took Dawg's advice and put it up on 2x6 and leaned it over and opened up the clutch release cover. Lost a little tranny fluid but not much to amount to anything.

The lever was in the up position so not sure if that was the issue or if taking it back off fixed or not but put it back together, readjusted the clutch and was able to get he free play out of the clutch cable. It still seems to take a bit more adjustment so maybe my cable is stretching a little but it was no where near the end of the cable adjustment as it was yesterday. Maybe it was because it was completely cool bike? It was cool yesterday but it had ran earlier when I was warming the oil.

How long does a clutch cable normally last?

Thanks for all the help guys.

 

I just changed my aluminum cover to a chrome cover and also have more slack in my clutch lever, not sure why, put everything back exactly the same.