Need help with clutch adjustment
Thread Starter
|
Road Master
Joined: Sep 2009
Posts: 787
Likes: 6
From: Charlotte NC
Need help with clutch adjustment
While adjusting the clutch on my bike I have run into an issue removing the slack. Once I adjusted it in the primary I adjusted the cable. It was very spongy and did not feel right. I then loosened the cable again and can not get the slack out now. When I go one direction it gets more loose and the other way does not get the slack out, This is not the stock cable but a braided cable from the Harley dealer but may not be a harley product. I threaded it to the point it about comes apart and is still not taking up the slack. Any help?
Extreme HDF Member
Joined: Sep 2010
Posts: 14,744
Likes: 402
From: Phoenix '53, '88, '09 Big Twins
inside the tranny trap door cover ( where the cable goes in) is a ball and ramp mechanism which converts the "pulling force" on teh cable into a pushing force on the rod which accuates the clutch.
your ***** may have slipped out of place--- get the cable as snug as you can and work the lever a few times slowly, then check and see if the cable can be further adjusted...you need to feel a positive resistance to the lever as you pull it.
this lever/ball/ramp thing is discussed in most service manuals
you slacken the cable
adjust the clutch
adjust the cable so that the lever action works the clutch smoothly
mike
your ***** may have slipped out of place--- get the cable as snug as you can and work the lever a few times slowly, then check and see if the cable can be further adjusted...you need to feel a positive resistance to the lever as you pull it.
this lever/ball/ramp thing is discussed in most service manuals
you slacken the cable
adjust the clutch
adjust the cable so that the lever action works the clutch smoothly
mike
Thread Starter
|
Road Master
Joined: Sep 2009
Posts: 787
Likes: 6
From: Charlotte NC
inside the tranny trap door cover ( where the cable goes in) is a ball and ramp mechanism which converts the "pulling force" on teh cable into a pushing force on the rod which accuates the clutch.
your ***** may have slipped out of place--- get the cable as snug as you can and work the lever a few times slowly, then check and see if the cable can be further adjusted...you need to feel a positive resistance to the lever as you pull it.
this lever/ball/ramp thing is discussed in most service manuals
you slacken the cable
adjust the clutch
adjust the cable so that the lever action works the clutch smoothly
mike
your ***** may have slipped out of place--- get the cable as snug as you can and work the lever a few times slowly, then check and see if the cable can be further adjusted...you need to feel a positive resistance to the lever as you pull it.
this lever/ball/ramp thing is discussed in most service manuals
you slacken the cable
adjust the clutch
adjust the cable so that the lever action works the clutch smoothly
mike
Grand HDF Member
Joined: Jan 2012
Posts: 4,459
Likes: 2,893
From: Oklahoma
When you make the hub adjustment inside the derby cover it is easy to mistake a rough spot in the adjuster threads for the contact point on the plunger. Back off the lock nut and use a wrench to screw in the adjuster and turn it back out several times, then screw it in slowly to feel for the contact point and you should be able to get your 1/2 to one turn out easily when the true plunger contact point has been felt.
The disc that the adjuster is threaded into will lose the slight looseness in the clutch basket when the contact point is reached. If you believe you have reached the contact point but the disc still moves easily you haven't really found the contact point. Keep screwing the adjuster in until the disc is solid against the outboard side of the clutch basket. Then screw the adjuster out and in to find the contact point, and adjust from there.
The disc that the adjuster is threaded into will lose the slight looseness in the clutch basket when the contact point is reached. If you believe you have reached the contact point but the disc still moves easily you haven't really found the contact point. Keep screwing the adjuster in until the disc is solid against the outboard side of the clutch basket. Then screw the adjuster out and in to find the contact point, and adjust from there.
Tourer
Joined: Jan 2016
Posts: 344
Likes: 10
From: Pensacola, FL
Trending Topics
Thread Starter
|
Road Master
Joined: Sep 2009
Posts: 787
Likes: 6
From: Charlotte NC
Thanks but as I mentioned in my original post I loosened the cable then adjusted the setting in the primary but when I went back to take the slack out of the cable it would not adjust. As it turned out it was the push rod that was hung up. Once I backed out the set screw and push rod and re-inserted it adjusted fine. Apparently the push rod can hang up on the set screw so when you back it out the push rod comes back also. A little playing with it and it worked fine. A local HD tech suggested this so I thank him. Also thanks for your suggestions everyone.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
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
Supporter
Joined: Jan 2007
Posts: 15,788
Likes: 5,625
From: along the shore of Mishigami
there is a step in the clutch adjustment about pulling in the clutch handle a couple of times to reseat the ramp/*****. Then adjust cable end play at the handle using the cable adjuster. I use a dime for the gap.
Club Member
Joined: Jun 2009
Posts: 5,323
Likes: 37
From: NJ
Put the cable adjuster back together. Then go back to the clutch basket.
Loosen the jam nut on the clutch basket a few turns and then turn that Allen nut into the basket until it contacts the basket. Then turn it in some more and back it out.
Then go in for the final adjustment and turn the center Allen in until it hits the basket and turn it back out 3/4 of a turn and hold it there and secure the lock nut on the clutch basket without turning the Allen screw you just backed out. Then go back and take the slack out of the cable with the cable adjuster nut.
Pull on the clutch cable out of the perch until you see a gap the size of a nickel. Then squeeze the clutch lever a few times and check again.
You should be ok at this point.
Loosen the jam nut on the clutch basket a few turns and then turn that Allen nut into the basket until it contacts the basket. Then turn it in some more and back it out.
Then go in for the final adjustment and turn the center Allen in until it hits the basket and turn it back out 3/4 of a turn and hold it there and secure the lock nut on the clutch basket without turning the Allen screw you just backed out. Then go back and take the slack out of the cable with the cable adjuster nut.
Pull on the clutch cable out of the perch until you see a gap the size of a nickel. Then squeeze the clutch lever a few times and check again.
You should be ok at this point.