Hi I just had to replace my clutch hub, pressure plate, and clutch cable on a 91 Sportster. Now I have everything reassembled and am trying to adjust the clutch. I followed all the steps and seem to have it adjusted correctly. With the derby cover off I can see the clutch mechanism maxing out all the way to the left when my clutch lever is all the way pulled in. Heres my question: when in gear, as I pull the clutch in and walk the bike backwards or forwards I hit a spot where I feel resistance, like it's in gear, but I push past this spot, and now the clutch works fine. If I release the clutch and repeat the process it does the same thing again. Is this normal? Is it because I don't have and tranny fluid in it? Or does something sound wrong? I'm thinking I'm gonna just have to fill her up with tranny fluid and do a test ride.

 

Sounds normal, stock clutch baskets are never concentric, that's why there are tight and loose spots in the chain.

 

Do just that! Take a short ride, to satisfy yourself everything seems OK, but then take a longer ride (not just round the block), which should settle your rebuilt clutch. Let us know how you get on.