Mastering Harley-Davidson Clutch Adjustment

Mastering Harley-Davidson Clutch Adjustment

Table of Contents:

1. Introduction
2. Tools Required for Clutch Adjustment
3. Removing the Derby Cover
4. Loosening the Clutch Cable
5. Adjusting the Clutch
6. Checking the Clutch Lever Slack
7. Tightening the Clutch Cable
8. Reinstalling the Derby Cover
9. Testing the Clutch Adjustment
10. Conclusion

Introduction

In this tutorial, we will guide you through the process of adjusting the clutch on your motorcycle. Specifically, we will be focusing on late model big twins, but the general principles apply to other models as well. By following these steps and using the necessary tools, you can ensure that your clutch is operating smoothly and efficiently. So, let's get started!

Tools Required for Clutch Adjustment

Before diving into the clutch adjustment process, it's important to gather the necessary tools. Here's a list of tools you will need:

• T27 Torx with a quarter-inch ratchet
• 11/16 wrench
• 9/16 wrench
• Half-inch wrench
• 7/32 Allen wrench
• Torque wrench

Having these tools on hand will make the process much easier and ensure a successful clutch adjustment.

Removing the Derby Cover

To begin the clutch adjustment, you'll need to remove the derby cover. This cover provides access to the clutch mechanism. Follow these steps to remove the derby cover:

1. Locate the five Torx head screws that secure the derby cover in place.
2. Use a T27 Torx bit and a quarter-inch ratchet to remove the screws.
3. Once all the screws are removed, carefully lift off the derby cover and set it aside.

Loosening the Clutch Cable

With the derby cover removed, the next step is to loosen the clutch cable to create slack in the clutch lever. Follow these steps to loosen the clutch cable:

1. Pull down the rubber boot covering the adjuster on the clutch cable.
2. Use a half-inch wrench to hold the adjuster portion of the cable.
3. Use a 9/16 wrench to loosen the lock nut located above the adjuster.
4. Rotate the adjuster counterclockwise to create slack in the cable and loosen the clutch lever.

Creating slack in the cable is crucial for proper clutch adjustment. Once the cable is loosened, we can move on to adjusting the clutch itself.

Adjusting the Clutch

Now that we have loosened the clutch cable, it's time to adjust the clutch. Follow these steps to adjust the clutch:

1. Locate the adjuster screw on the clutch mechanism.
2. Hold the adjuster screw in place using a 7/32 Allen wrench.
3. Use an 11/16 wrench to loosen the lock nut on the adjuster screw.
4. Back off the adjuster screw until you feel it lightly touch the clutch mechanism.
5. After the initial touch, rotate the adjuster screw a half to a full turn in the counterclockwise direction.
6. Once you have completed the adjustment, tighten the lock nut using an 11/16 wrench.

Adjusting the clutch ensures that it engages properly and allows for smooth shifting. It's essential to follow these steps carefully to achieve the desired results.

Checking the Clutch Lever Slack

After adjusting the clutch, we need to check the amount of slack in the clutch lever. Follow these steps to check the clutch lever slack:

1. Return to the clutch cable adjuster near the handlebars.
2. Use the long adjuster nut and run it down to remove the slack in the cable.
3. Aim for approximately an eighth of an inch of play in the clutch lever. This means the lever should move in and out by about an eighth of an inch.
4. Adjust the nut accordingly until the desired clutch lever slack is achieved.
5. Once the adjustment is made, tighten the lock nut.

Having the correct amount of slack in the clutch lever is crucial for smooth and responsive clutch operation.

Tightening the Clutch Cable

With the clutch adjustment and lever slack checked, it's time to tighten the clutch cable. Follow these steps to tighten the clutch cable:

1. Use the long adjuster nut to run it back down, removing the slack from the cable.
2. Gradually tighten the nut until the cable feels tight and the clutch lever is firm.
3. Avoid over-tightening the cable, as it can lead to clutch slippage or premature wear.

By following these steps, you can ensure that the clutch cable is properly tightened and ready for use.

Reinstalling the Derby Cover

Once the clutch adjustment is complete and the cable is tightened, it's time to reinstall the derby cover. Follow these steps to reinstall the derby cover:

1. Check the gasket on the derby cover for any signs of damage or wear. If needed, replace the gasket.
2. Carefully place the derby cover back onto the clutch mechanism.
3. Align the screw holes and insert the Torx head screws.
4. Use a torque wrench to tighten the screws to approximately 10 Newton meters or 85 inch pounds.

Reinstalling the derby cover ensures proper sealing and protects the clutch mechanism from dust and debris.

Testing the Clutch Adjustment

With the clutch adjustment complete and all components reinstalled, it's time to test the clutch. Take your motorcycle for a short ride and pay attention to its performance. If you experience clutch creep or excessive movement in the clutch lever, it may be necessary to readjust the clutch. Ensure that your clutch is in good working order to maintain smooth and efficient operation.

Conclusion

Adjusting the clutch on your motorcycle is a straightforward process that can greatly improve its performance. By following the steps outlined in this tutorial and using the right tools, you can make the necessary adjustments and ensure that your clutch operates smoothly and efficiently. Remember to check your clutch regularly and make adjustments as needed to maintain optimal performance. If you have any questions or need further assistance, feel free to reach out to us via phone, online chat, or by leaving a comment below. Now, go out there and enjoy your ride with a properly adjusted clutch!

Highlights:

• Learn how to adjust the clutch on your motorcycle
• Step-by-step instructions for a successful clutch adjustment
• Important tools required for the process
• Checking and adjusting the clutch cable
• Proper clutch adjustment for smooth shifting
• Ensuring the right amount of clutch lever slack
• Tightening the clutch cable to avoid slippage
• Reinstalling the derby cover and testing the clutch
• Tips for identifying the need for clutch adjustment
• Maintaining a well-functioning clutch for optimal performance

FAQ

1. Q: Why is clutch adjustment necessary? A: Clutch adjustment is necessary to ensure smooth shifting and optimal performance of the clutch mechanism. It helps in preventing clutch slippage and extends the lifespan of the clutch components.

2. Q: How often should I adjust my clutch? A: It is recommended to check and adjust the clutch every 5,000 to 10,000 miles or whenever you notice any issues with clutch engagement or lever movement.

3. Q: Can I adjust the clutch myself, or should I seek professional help? A: Clutch adjustment can be done by following the provided steps, but if you are unsure or uncomfortable with the process, it is advisable to seek professional assistance from a qualified mechanic.

4. Q: What are the signs that my clutch needs adjustment? A: Signs that your clutch may need adjustment include difficulty shifting gears, clutch slippage, excessive lever movement, or clutch creep (the bike tries to move when the clutch is pulled in).

5. Q: How do I know if my clutch adjustment was successful? A: After adjusting the clutch, you can test it by taking your motorcycle for a short ride. Pay attention to the clutch engagement, shifting smoothness, and overall performance. If you notice any issues, recheck the adjustment or consult a professional.

Resources:

• JP Cycles