Clutch Adjustment
Once the 'clutch basket' setting is done with the proper play (according to the manual), the cable can be set so that the clutch breaks open as soon as the round corner of the white nylon spacer becomes visible.
Loosen the jam nuts on the clutch cable. They are under the rubber boot.
Put maximum slack in the cable.
Remove screws in derby cover.
Use an 11/16 wrench or socket to loosen jam nut on clutch adjusting screw.
I always put the transmission in 4th or 5th gear at this point.
With the transmission in gear, you can step on the rear brake pedal so the clutch basket does not turn when you loosen the jam nut.
With the jam nut loose, take your allen tool and turn the allen head "In" till it gently bottoms out. Do this several times until you have a good feel for it.
Once you are satisfied it is all the way in, turn the allen "Out" about 3/4 of a turn.
This is your clutch adjustment.
Now, use your 11/16 wrench (socket) and tighten the jam nut. This is where you stand on the rear brake pedal so the clutch basket does not turn.
Make the jamb nut snug, but don't twist the threads off.
Now put the derby cover back on.
Go back to the clutch cable adjuster and tighten it back up so you take all the slack out of the clutch lever. The cable is adjusted when you can slide a dime between the ferrule and the housing at the lever. Set the jamb nuts and pull the rubber cover down.
Now squeeze the clutch lever a couple of times to set everything.
Your done. Go out for a ride to test it out.
I paraphrased a lot here for those who don't have a manual, but I would recommend that you pop for the $60.00 service manual if you enjoy this sort of thing. You will usually pay for the service manual the first time you take it to the dealer for service. Servicing a Harley is pretty simple stuff, so simple that my wife can do it. She used to have trouble putting a diaper on a baby too. Your biggest investment will be in basic hand tools. You don't need a set of $5000.00 Snap On Tools because you are not going to be making a living turning wrenches. I would think you could spend $100.00 at the local Walmart and get enough tools to do most service such as fluid changes and clutch adjustments. When something pops up that is above your comfort level, take it to the dealer and help send his kids to college, instead of yours.
Loosen the jam nuts on the clutch cable. They are under the rubber boot.
Put maximum slack in the cable.
Remove screws in derby cover.
Use an 11/16 wrench or socket to loosen jam nut on clutch adjusting screw.
I always put the transmission in 4th or 5th gear at this point.
With the transmission in gear, you can step on the rear brake pedal so the clutch basket does not turn when you loosen the jam nut.
With the jam nut loose, take your allen tool and turn the allen head "In" till it gently bottoms out. Do this several times until you have a good feel for it.
Once you are satisfied it is all the way in, turn the allen "Out" about 3/4 of a turn.
This is your clutch adjustment.
Now, use your 11/16 wrench (socket) and tighten the jam nut. This is where you stand on the rear brake pedal so the clutch basket does not turn.
Make the jamb nut snug, but don't twist the threads off.
Now put the derby cover back on.
Go back to the clutch cable adjuster and tighten it back up so you take all the slack out of the clutch lever. The cable is adjusted when you can slide a dime between the ferrule and the housing at the lever. Set the jamb nuts and pull the rubber cover down.
Now squeeze the clutch lever a couple of times to set everything.
Your done. Go out for a ride to test it out.
I paraphrased a lot here for those who don't have a manual, but I would recommend that you pop for the $60.00 service manual if you enjoy this sort of thing. You will usually pay for the service manual the first time you take it to the dealer for service. Servicing a Harley is pretty simple stuff, so simple that my wife can do it. She used to have trouble putting a diaper on a baby too. Your biggest investment will be in basic hand tools. You don't need a set of $5000.00 Snap On Tools because you are not going to be making a living turning wrenches. I would think you could spend $100.00 at the local Walmart and get enough tools to do most service such as fluid changes and clutch adjustments. When something pops up that is above your comfort level, take it to the dealer and help send his kids to college, instead of yours.
I adjust my clutch exactly as Retrop described except I go 1 turn rather than 3/4 turn for freeplay at the clutch (personal preference), and then I adjust the cable to position the clutch engagement relative to the grip, while ensuring adequate freeplay in the lever.
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