The bike came with a broken hand clutch lever so I've haven't tested the clutch yet. I finally got a lever, hooked up the cable, and adjusted the clearance at the clutch release lever at 13/16". Right now I'm at the very end of the sleeve on the cable adjuster. Is this an indicator that the clutch is worn and needs servicing, or do I need to pull the clutch and check?

Thanks
Nick

 

This might help. I'm thinking that your "13/16" is a typo and you meant "3/16" which would be in between what the 2 links below say.




https://cycleheart.wordpress.com/201...79-harley-fxe/

 

13/16" came out of the manual I have:

 

I think it's been about 20 years since I've adjusted the clutch on my 1978 FXE but I can't remember ever taking a measurement at the lever. I probably was doing it wrong. Anyway, here's what my book says and it also has the 13/16" measurement. My bike is a 1978 and has the other transmission so it uses a different measurement. My book covers 1978 1/2 to 1908 FL - FX models.

 

I think I figured it out. Hopefully this makes sense. Once I set the correct distance between the clutch release lever and the top of the ratchet top per the service manual, apparently I never turned the screw back in all the way.

Tonight I took off the pushrod lock nut, and turned the screw all the way in, then backed it out 1/8 turn. The clutch release lever doesn't have any more play when the cable tension is off like it did when I first started. When I adjusted the cable tension again, I was still at the end of the adjustment sleeve, but the hand lever was tighter and I was able to pull the clutch in, put it in gear and turn the wheel with the clutch engaged and bike in gear.

Once I put the new jets in my carb and re-install everything, I should be able to test the clutch with the bike running.
Nick

 

Temperatures were mild this weekend here in CT and I had some time to work on the bike. I was able to adjust everything per the manual and ran the bike on the stand. I know its not perfect but the clutch is operational and the transmission works so I'm happy.

 

Thanks for the update.