Clutch adjustment wierdness.
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Stellar HDF Member
Joined: Nov 2007
Posts: 2,121
Likes: 300
From: New Mexico-No, you don't need a passport.
Clutch adjustment wierdness.
95 Flht with a six speed gear set from ultimate accessories.
The clutch cable and a new throw out bearing were replaced last year.
I adjusted the clutch.
I was cold.
I loosened the cable adjuster.
I loosened the clutch jam nut and backed out the clutch adjuster.
I turned it in until it touched the clutch.
I backed out the adjuster 1/2 turn and tightened the jam nut.
I readjusted the cable leaving an eighth in of play in the cable.
It seemed like it used a whole lot of the adjuster to get the cable play set.
The clutch works good and neutral is relatively easy to find.
The clutch engages when I release the lever.
The clutch disengages when I pull the lever.
The problem?
When I pull the lever all of the way in it is still about 1/4 to 1/2 inch from the grip.
Is this normal?
It just doesn't seem right.
The clutch cable and a new throw out bearing were replaced last year.
I adjusted the clutch.
I was cold.
I loosened the cable adjuster.
I loosened the clutch jam nut and backed out the clutch adjuster.
I turned it in until it touched the clutch.
I backed out the adjuster 1/2 turn and tightened the jam nut.
I readjusted the cable leaving an eighth in of play in the cable.
It seemed like it used a whole lot of the adjuster to get the cable play set.
The clutch works good and neutral is relatively easy to find.
The clutch engages when I release the lever.
The clutch disengages when I pull the lever.
The problem?
When I pull the lever all of the way in it is still about 1/4 to 1/2 inch from the grip.
Is this normal?
It just doesn't seem right.
Seasoned HDF Member
Joined: Mar 2010
Posts: 38,591
Likes: 6,435
From: Honah Lee
If it was not that way before starting due to poorly made cable that is not correctly made for the proper cable and sheath lengths, my guess is when you screwed in in to touch no play, what you felt was that fine thread distorted slightly from the locknut.
Do no back cable length all the way. You need to fill some clutch with lever Then when you go for the touch for no play, once you hit it, go on in a few turns to debur screw. Now back back and go back in for no play. Do it two or three times but pull clutch lever so you actually fill the no play. This also get cam ***** in full fwd position.
Now with lever free and some noticeable play in cable, touch and back off 1/2 turn. Hold it with Allen and tighten locknut with box. That fine thread does not take much torque.
Check cable Freeplay at both locks setting cable at 1/32-1/16 max. It just gets loose.
Do no back cable length all the way. You need to fill some clutch with lever Then when you go for the touch for no play, once you hit it, go on in a few turns to debur screw. Now back back and go back in for no play. Do it two or three times but pull clutch lever so you actually fill the no play. This also get cam ***** in full fwd position.
Now with lever free and some noticeable play in cable, touch and back off 1/2 turn. Hold it with Allen and tighten locknut with box. That fine thread does not take much torque.
Check cable Freeplay at both locks setting cable at 1/32-1/16 max. It just gets loose.
Last edited by Jackie Paper; May 23, 2019 at 10:21 AM.
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
95 Flht with a six speed gear set from ultimate accessories.
The clutch cable and a new throw out bearing were replaced last year.
I adjusted the clutch.
I was cold.
I loosened the cable adjuster.
I loosened the clutch jam nut and backed out the clutch adjuster.
I turned it in until it touched the clutch.
I backed out the adjuster 1/2 turn and tightened the jam nut.
I readjusted the cable leaving an eighth in of play in the cable.
It seemed like it used a whole lot of the adjuster to get the cable play set.
The clutch works good and neutral is relatively easy to find.
The clutch engages when I release the lever.
The clutch disengages when I pull the lever.
The problem?
When I pull the lever all of the way in it is still about 1/4 to 1/2 inch from the grip.
Is this normal?
It just doesn't seem right.
The clutch cable and a new throw out bearing were replaced last year.
I adjusted the clutch.
I was cold.
I loosened the cable adjuster.
I loosened the clutch jam nut and backed out the clutch adjuster.
I turned it in until it touched the clutch.
I backed out the adjuster 1/2 turn and tightened the jam nut.
I readjusted the cable leaving an eighth in of play in the cable.
It seemed like it used a whole lot of the adjuster to get the cable play set.
The clutch works good and neutral is relatively easy to find.
The clutch engages when I release the lever.
The clutch disengages when I pull the lever.
The problem?
When I pull the lever all of the way in it is still about 1/4 to 1/2 inch from the grip.
Is this normal?
It just doesn't seem right.
What brand clutch cable did you go with?
I guess the main thing is your clutch works so why not just run it the way it is?
Seasoned HDF Member
Joined: Mar 2010
Posts: 38,591
Likes: 6,435
From: Honah Lee
I think if you use it like that, you are using the end of the barrel on cable with both the clutch load and how hard you ram it into the end of the movement.
Ultimate HDF Member
Joined: Jul 2014
Posts: 5,649
Likes: 430
From: MASS_hole
I like engagement just at about 1/4 of that initial pull on the lever.
I usually back off the allen nut 1/4 turn after it touches.
works for me. Stock clutch and cable with 30k mi on it. YMMV
I usually back off the allen nut 1/4 turn after it touches.
works for me. Stock clutch and cable with 30k mi on it. YMMV
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
The barrels on the ends of the outer sheath will never get more stress on them than you put there when adjusting.
OP's problem seems to be an inner cable that is too short for his application.
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Seasoned HDF Member
Joined: Mar 2010
Posts: 38,591
Likes: 6,435
From: Honah Lee
Understand exactly what you just said. However, my lever stops when it hits the bar. So the only load is the clutch pull. His is the clutch pull plus however hard he is pulling after it runs out of travel of the inner cable.
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Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
Exactly...
That's why I said his problem is his inner cable is too short.
The inner cable being too short isn't gonna add any extra tension to the cable jacket.
Ultimate HDF Member
Joined: Jul 2014
Posts: 5,649
Likes: 430
From: MASS_hole
Inner cable, meaning clutch cable connected to the lever?
Only cable I know of LOL
Don’t understand how it can be too short.
I know correct length is vital for proper function. But too short and clutch is always engaged.
I like longer cables when ever possible
Only cable I know of LOL
Don’t understand how it can be too short.
I know correct length is vital for proper function. But too short and clutch is always engaged.
I like longer cables when ever possible