Clutch issue
Thread Starter
|
Tourer
Joined: Feb 2017
Posts: 361
Likes: 56
From: Lancaster, CA.
Clutch issue
My 2003 FXDWG has had a clutch that does'nt engage until lever is almost completely released. It's been adjusted by two competent mechanics and the clutch pack has been replaced. I would really like to get it to work like my 2015 FXDL. It does have the easy clutch cam installed, but I'm pretty sure it was the same before and after the cam change. Any ideas ?
Thread Starter
|
Tourer
Joined: Feb 2017
Posts: 361
Likes: 56
From: Lancaster, CA.
I actually replaced the pack trying to cure this. It's been frustrating.
Thread Starter
|
Tourer
Joined: Feb 2017
Posts: 361
Likes: 56
From: Lancaster, CA.
I'm curious, if I just backed out the screw in the clutch assy, would this move the release point, or just create slack ?
Club Member
Joined: Dec 2007
Posts: 4,192
Likes: 168
From: Knoxville, Tn
Clutch Adjustment
Steps 1. Start with a completely cold bike.
2. Slack cable as much as possible.
3. Remove derby cover.
4. Put the wrench on the adjuster shaft.
5. Break the torque on the jam nut.
6. Back out the adjuster shaft a couple of turns.
7. Pull the clutch lever into the handle bars.
8. While holding the clutch lever against the handle bars, turn the adjuster shaft in.
9. When the clutch lever starts to pull away from the handlebars, stop turning the adjuster.
10. Back out the adjuster 3/4 turn to 1 full turn and hold the adjuster with a wrench and torque the jam nut on the adjuster.
11. Reinstall the derby cover with fluid if needed.
12. Go back to the cable and start turning the adjuster there to put more tension on the cable, by making the cable longer. Adjust it until you have about an 1/8" of play
13. Put a dab of grease on the adjuster and slide the rubber cover the adjuster.
If you have done the adjustment properly, the clutch will start to engage when the lever leaves the handlebars. If the cable is installed wrong or the ***** are not on the ramp, look up that in your maintenance manual.
Put the bike on the side stand with apiece if a 2x4 under the stand. If you have a scissors jack, then just jack it up aft of the transmission. Failure to do this step will put primary fluid in the floor. The bike needs to be level.
2. Slack cable as much as possible.
3. Remove derby cover.
4. Put the wrench on the adjuster shaft.
5. Break the torque on the jam nut.
6. Back out the adjuster shaft a couple of turns.
7. Pull the clutch lever into the handle bars.
8. While holding the clutch lever against the handle bars, turn the adjuster shaft in.
9. When the clutch lever starts to pull away from the handlebars, stop turning the adjuster.
10. Back out the adjuster 3/4 turn to 1 full turn and hold the adjuster with a wrench and torque the jam nut on the adjuster.
11. Reinstall the derby cover with fluid if needed.
12. Go back to the cable and start turning the adjuster there to put more tension on the cable, by making the cable longer. Adjust it until you have about an 1/8" of play
13. Put a dab of grease on the adjuster and slide the rubber cover the adjuster.
If you have done the adjustment properly, the clutch will start to engage when the lever leaves the handlebars. If the cable is installed wrong or the ***** are not on the ramp, look up that in your maintenance manual.
Put the bike on the side stand with apiece if a 2x4 under the stand. If you have a scissors jack, then just jack it up aft of the transmission. Failure to do this step will put primary fluid in the floor. The bike needs to be level.
Last edited by dyna rider; Oct 24, 2017 at 05:04 PM.
Thread Starter
|
Tourer
Joined: Feb 2017
Posts: 361
Likes: 56
From: Lancaster, CA.
Steps 1. Start with a completely cold bike.
2. Slack cable as much as possible.
3. Remove derby cover.
4. Put the wrench on the adjuster shaft.
5. Break the torque on the jam nut.
6. Back out the adjuster shaft a couple of turns.
7. Pull the clutch lever into the handle bars.
8. While holding the clutch lever against the handle bars, turn the adjuster shaft in.
9. When the clutch lever starts to pull away from the handlebars, stop turning the adjuster.
10. Back out the adjuster 3/4 turn to 1 full turn and hold the adjuster with a wrench and torque the jam nut on the adjuster.
11. Reinstall the derby cover with fluid if needed.
12. Go back to the cable and start turning the adjuster there to put more tension on the cable, by making the cable longer. Adjust it until you have about an 1/8" of play
13. Put a dab of grease on the adjuster and slide the rubber cover the adjuster.
If you have done the adjustment properly, the clutch will start to engage when the lever leaves the handlebars. If the cable is installed wrong or the ***** are not on the ramp, look up that in your maintenance manual.
Put the bike on the side stand with apiece if a 2x4 under the stand. If you have a scissors jack, then just jack it up aft of the transmission. Failure to do this step will put primary fluid in the floor. The bike needs to be level.
2. Slack cable as much as possible.
3. Remove derby cover.
4. Put the wrench on the adjuster shaft.
5. Break the torque on the jam nut.
6. Back out the adjuster shaft a couple of turns.
7. Pull the clutch lever into the handle bars.
8. While holding the clutch lever against the handle bars, turn the adjuster shaft in.
9. When the clutch lever starts to pull away from the handlebars, stop turning the adjuster.
10. Back out the adjuster 3/4 turn to 1 full turn and hold the adjuster with a wrench and torque the jam nut on the adjuster.
11. Reinstall the derby cover with fluid if needed.
12. Go back to the cable and start turning the adjuster there to put more tension on the cable, by making the cable longer. Adjust it until you have about an 1/8" of play
13. Put a dab of grease on the adjuster and slide the rubber cover the adjuster.
If you have done the adjustment properly, the clutch will start to engage when the lever leaves the handlebars. If the cable is installed wrong or the ***** are not on the ramp, look up that in your maintenance manual.
Put the bike on the side stand with apiece if a 2x4 under the stand. If you have a scissors jack, then just jack it up aft of the transmission. Failure to do this step will put primary fluid in the floor. The bike needs to be level.
Trending Topics
Supporter
Joined: Jan 2007
Posts: 15,787
Likes: 5,610
From: along the shore of Mishigami
Fill the primary with 26 ozs. of fluid, that's what's called for in my '02 and '05 Dyna's. Just for info.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
