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Discussion Starter · #1 ·
2007 Vegas with Vic chrome primary cover and Vic hydraulic clutch.

The clutch lever won't return all the way. When engaging the engine, it hangs up at the last inch. However, if I move the clutch pinion at the primary cover by hand, the lever fully returns. (I don't get clutch slip, unless it's pushed really hard when hot.) So originally, I thought the return spring in the slave cylinder was going bad/weak even though it's only 4 or 5 years old. But I also noticed that when I move the clutch pinion all the way so it returns the lever fully, I hear and feel the clutch (rack?) tapping/knocking against the primary cover. Is that abnormal? It's almost like the cover keeps the clutch assembly from completely moving and allowing the clutch lever to return to the full out position...and engage the engine just a tad which can then only be felt when running it hard with WOT.

I won't get to opening it up until next week but not sure that will tell me a whole lot any way. It sounds and feels like a mechanical problem at the cover rather than the slave cylinder. Thoughts? Cuz i really hate the thought of screwing around with the slave cylinder again...it's a cramped work space.
 

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your clutch adjuster screw on the clutch itself might need adjusting.
If you hear noise on the inside i wouldn't ride it till you look inside.
Are they the stock clutch plates ??
 

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I had a problem once with my clutch slipping and realized the nylon bushing screw holding the clutch lever had somehow tightened itself to the point where the clutch lever would not function properly.?????
 

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Discussion Starter · #5 ·
Thanks for giving it some thought. Lever mechanism is in good shape.
I'm thinking that maybe the actuating rod from the slave cylinder to the pinion might be bent. The slave sits real close to the chromed battery box cover...the cover seems to extend below where it 'should' so maybe something got stuck in there and did some damage. Just guessing what could possibly be wrong?

The sound and feel of the clutch rack (?) knocking against the primary cover still has me scratching my head. Maybe it normally does this but I don't remember hearing that with any other bike in my 50 years of riding and being around bikes.
 
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