HarleyTechTalk

Hi Folks  I have an older 5 speed in my bike and the clutch mechanizum has a clicking noise when I pull the leaver in or out I have had it apart and all the parts seem to be in good working order , no ware, I cleaned it all put it back togetherbut I get this weird click or knock . can anyone give me a clue as to what ive done wrong or whats wrong with my release mechanizum. I have owned a few bikes with 5 speeds and never heard this noisr before.

What model year clutch are we discussing?

...and to be clear, it was okay (no click) before you disassembled/cleaned & re-assembled, correct?

Have you replaced the cable?
Is your handle perch worn?

Have you tracked down where the noise is, at the top near the handle, at the cable adjuster, at the tranny side cover, at the primary side?

thanks to all the contributors that make this site such a good place to get info. but I have a clunk coming from the clutch release bearing area. I have had the cover of and all parts look clean ,no wear and the fit as they should. but when I pull the clutch lever in or let it out i can hear a clunk ,like a ball bearing in the clutch release is hung up. what can it be?

I have the same noise coming from my clutch release mechanizum. all parts look good and the clutch work great, but this clunk drives me crazy.

You have a thread going already describing a click in the clutch release mechanism, is this the same sound you are talking about here, or a new issue?
Questions were asked in the other thread, but not answered.

Quote from: vern on May 15, 2024, 09:11:07 AMI have the same noise coming from my clutch release mechanizum. all parts look good and the clutch work great, but this clunk drives me crazy.

Are you responding to your own thread with the same problem?

I'll take a shot at responding here on this thread...
It may be beneficial if You provide the Year, and Model of the Bike...if it is the Original Clutch Pack, Mileage on the Machine, etc.
Does it make the Noise when the Bike is not running?
Or only while running?

Maybe way off base here, but there was a couple times, it's been about 20 years ago,  when I had bikes coming in a similar condition- lever felt "crunchy". Both were cop bikes, early 2000s, same department, different riders, and both had loose battery cables- and somehow the clutch cable provided a ground for the system, effectively micro welding the balls, to the ramp, in the clutch release assembly. Repaired the grounds, and replaced the clutch cables, and B&R assemblies. Haven't seen one like that since.

I've heard of that but never have witnessed one.

I got a little confused and replyed to my post. the noise is definatly coming from the tranny cover on the exhaust side . goes away after abit of a ride, I adjusted the cable as per the book but it always crunched into gear so i tightened up the adjuster and there was less noise andit shifted much better also putting it into gear is also smoother. Seems that the part that holds the ball bearings is loose in the housing and adjusting it needs to be tighter. Interesting about the ground theory. also its a shovel 5 speed in a shovel softail frame, custom!

Would a throw out bearing cause this noise?

Quote from: smoserx1 on May 15, 2024, 03:42:39 PMWould a throw out bearing cause this noise?

I would say it's a possibility and wouldn't rule it out.

the throwout bearing looks fine and the hand operation is smooth  just when i begin to use up the free play it clunks or clicks depending on your hearing , I have adjusted almost all the free play out of the adjuster, goes into gear nice shifts nice smooth action on the clutch, what could posibly be wrong?

Take the pushrod parts out of the transmission and inspect them for damage. Inspect the pressure plate to see that it slides smoothly. Inspect the spring to see that it's not damaged somehow, inspect the clutch basket to see if the plates are hanging up, inspect the release ramps for strange wear or damage. Check the clutch cable for what rigidthumper said about having been used as a ground.

There are only so many parts that move when the clutch lever is pulled. So they all need to be checked.

I had this problem on a bicycle brake before. The inner cable had a burr on it. Actually one of the strands had broken and was dragging inside the housing. If the break was where the inner cable goes in and out of the housing I can imagine it might make a clicking sound.

Thanks for all the replyes to my question.i found the problem and fixed it. I am a tinker and builder and not to much of anything else, and it takes me a bit to figure things out. Most of the problems I have with bike building is that I have to spend a bit of time thining about what Im going to do or repair or create. but if I spend enought time tinkering I get it. I had fastened my clutch cable to my crash guard, not to tight just enough to stop it from hitting my crash guardand making a rattle sound. well it stoped the rattle but it kinked the clutch cable just enough to bind the cable, so that when i pulled in my clutch leaver it would bind and then loosen up enough to let go of the cable and make a clicking noice. I really had to laugh at myself for doing this. to much tinkering I guess or maybe not enough, any way enjoy your ride.

Glad you found it.
The classic "what did you do right before the problem started?"

Good find.  Thanks for sharing your discovery.

Wow - there's some good diagnostic work right there!

Quote from: rigidthumper on May 15, 2024, 11:48:50 AMMaybe way off base here, but there was a couple times, it's been about 20 years ago,  when I had bikes coming in a similar condition- lever felt "crunchy". Both were cop bikes, early 2000s, same department, different riders, and both had loose battery cables- and somehow the clutch cable provided a ground for the system, effectively micro welding the balls, to the ramp, in the clutch release assembly. Repaired the grounds, and replaced the clutch cables, and B&R assemblies. Haven't seen one like that since.