So I had the shifter shaft break on my 89 sportster. Took the transmission apart to replace the broken part. Put it back together, and I am having a heck of a time getting the clutch adjusted just right.

Followed the directions in the service manual, Tightened the clutch adjusting nut to snug, backed off a quarter turn. Adjusted the clutch barrel adjuster to a dime gap at the lever.

So I have a really tough time finding neutral when stopped, rolling is fine. When it is cold, it's is really tough. Doesnt idle well in 1st, (wants to die). I have loosens and tighten the clutch tension, doesn't seem to make a difference.

I have about 800 miles on it since the repair, and it is marginally better, but not mutch. Shifts good through all the gears while rolling, clutch doesn't slip.

Any suggestions are appreciated.

 

Sounds like your clutch is dragging. Try the simplified procedure in the sticky area of the clutch forum. Worked great for me...

Also,
- you didn't mention loosening the cable to slack before adjusting the nut.make sure you do that ..
- adjust only when fully cooled off
- use the proper lube, like HD Formula+, in the primary.

 

Maybe if you post this question in the Sportster section maybe they can help out.

 

If you have too much or too thick of oil in your primary you will experience the exact same thing.

 

Did you install the clutch dish spring backwards?

I had an idiot indy do that to me and it burned out brand new clutch plates fast.