Bought my 2002 xl1200 bout a month ago and changed my primary/trans. Fluid and added Mobil 1 75/90 and dumped in 1qt. Trying to get the bike to shift right has been a chore. Did the clutch and cable adjustment maybe 8-10 times and it either jerks in first, creeps on me at a stop while in first, and somtimes can't get her to shifts into a higher gear, and last but not lease grind, clunk into first. Is it time for a new clutch pack? I've turned out the screw in the primary any where for 1/4 turn to 1/2 to 1 full turn, I just can't get a good adjustment. If I need a clutch pack and springs do you suggest any one over the other. I am running a stage 1 on my scoot. The scoot has 52k on her and don't know what has and has not been done. I've changed motor oil and primary so far just so you know. boy this is driving me nuts!

 

I would ALWAYS use sportster primary and trans oil from the bike shop. Gear oil in a trans is ok but the primary might make shifting a hassle. On a big twin they are separate so it's possible, but on a sportster it's shared. Try the right stuff. Then if there is still a problem you know it's not the choice of oil. Also get a factory service manual so you know the proper fluid amounts. I doubt it's one quart.

 

Yeah I run Red Line 75W90 gear oil with great results. Charley on this form has 100,000 miles on Mobil I 75W90 gear oil with out any issues. Probably your clutch. Oh and it is one (1) quart.

 

My mistake then. Thank you for the correction hex.

 

When you say you turned the screw out,you mean you turned it in (clockwise )a 1/4 turn?

 

Yeah you turn it in till it stops and then turn it out 1/4 turn and adjust the free play at the lever.

 

Counter clockwise tell you feel resistance,then clockwise a 1/4 turn.

maybe try this

Here is an almost fool proof method for clutch adjustment. It takes the guesswork out of the "feel" for the adjuster.
Once you have opened up the derby cover and are ready to proceed...

1)Collapse the adjuster on the cable sleeve all the way.

2)Pull the lever against the bar and hold it there with slight force.

3)Turn the pushrod adjuster bolt in while holding the lever against the bar lightly until it starts to force the lever away for some distance. (Do this more than once to get the feel). While keeping light pressure on the lever back the adjuster bolt out just until the lever touches the bar again and then another little bit, about 1/2 turn , then lock it.

4)Adjust the cable freeplay at the lever for 1/16" free play.

You should be good to go .

Always adjust the clutch on a cold bike for best results.

 

are you kidding, Ive been doing it so many times i could do it with my eyes closed, I have done like I said 1/4 turn, 1/2 turn, full turn, over and over thats whats got me. But thanks for the response.

 

Haha,sorry when i read it,it sounded backwards,maybe try the other way i posted you don't have anything to lose.
Good luck

 

when you say " for some distance " how far is that, off the bar?