Question about 2005 Harley Davidson FLHTC - FLHTCI Electra Glide classic

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2005 FLHTCI Clutch Adjustment

I have a 2005 FLHTCI. The clutch cable has too much slack. How do I tighten up the cable?

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  • Anonymous Mar 15, 2014

    How can I take the slack out of the clutch lever on my 2005 FXSTI H.D. Softail

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Follow the bable down from the lever approx 2 feet....right infront of the front cylinder...there is a rubber boot on the cable...pull back the boot to expose the adjuster....it will have a lock nut that you need to loosen...you will need 2 wrenches to do this...once the nut is loose you can make minor adjustments to the cable...remember to leave some slack in the cable....check the slack at the lever...iusually make it just a little under 1/8 of an inch.....if it wont adjust all the slack out, then you will need to adjust the clutch release mechanism under the round cover on the primary....i would suggest picking up a service manual

Posted on Apr 19, 2009

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1 Answer

How to adjust clutch inside primary case?


Because the clutch cable adjuster clearance increases with engine temperature, adjust
the clutch when the engine is cold. If the clutch is adjusted when the engine is hot, insufficient pushrod clearance can cause the clutch to slip.
1. Remove the clutch mechanism inspection cover and
quad ring
2. Remove the clamp and slide the rubber boot off the clutch in-line cable adjuster.
3. Loosen the adjuster locknut and turn the adjuster to provide maximum cable slack.
4. Make sure the clutch cable seats squarely in its perch at the handlebar.
5. At the clutch mechanism, loosen the clutch adjusting screw locknut and turn the adjusting screw clockwise until it is lightly seated.
6. Squeeze the clutch lever three times to verify the clutch balls are seated in the ramp release mechanism located behind the transmission side cover.
7. Back out the adjusting screw counterclockwise 1/2 to 1 turn. Then hold the adjusting screw and tighten the locknut to 72-120 in.-lb.(8-14 N•m).
8. Once again, squeeze the clutch lever to its maximum limit three times to set the clutch ball and ramp release mechanism.
9. Check the free play as follows:
a. At the in-line cable adjuster, turn the adjuster away from the locknut until slack is eliminated at the clutch hand lever.
b. Pull the clutch cable sheath away from the clutch lever, then turn the clutch cable adjuster to obtain the clearance gap
c. When the adjustment is correct, tighten the clutch in-line cable locknut and slide the rubber boot over the cable adjuster.
10. Install the clutch inspection cover quad ring onto the primary chain case cover.
11. Install the clutch inspection cover and tighten the screws to 84-108 in.-lb. (9.5-12 N•m).

Jul 23, 2014 | 2000 Harley Davidson FXDWG Dyna Wide Glide

1 Answer

How to clutch adjustment


Hi, Anonymous, leave the slack for now. Remove large round clutch inspection cover and back off clutch adjusting screw lock nut. Screw in adjusting screw untill resistance is felt then back off 1/4 turn. Tighten jam nut and replace inspection cover. With silicone or brake kleen spray the top inside of rubber boot covering clutch adjuster and slide it away. Back off jam nut and adjust cable so that when pulling on the clutch lever with one hand and the clutch cable with the other you obtain 1/16" to 1/8" freeplay. Tighten jam nut, slide rubber boot back on and your good to go. Good luck

Apr 08, 2014 | 2000 Harley Davidson FXST Softail Standard

1 Answer

1st and 2nd gear keep jumping out of gear


You may want to make sure the clutch cable is properly adjusted. At the clutch lever on the handlebars, pull back the rubber cover over the end of the cable where it goes into the lever. You'll find a round lock wheel that you tighten to prevent the clutch cable adjustment from moving. Loosen that wheel then you can turn the clutch cable adjustment in or out to adjust the clutch engagement and take up. For those bikes, you want to adjust it so that there is a small amount of slack in the clutch lever. Look at the "crack" where the lever pivots when you pull on it. Adjust the clutch cable by turning that adjustment in or out until you have just barely enough opening to slip a nickel edge into the very outside of that "crack" when you apply very, very light pressure to the clutch lever (just enough pressure to take the slack out of the lever). Tighten the lock wheel back into place and try it now. Also, make sure you are using a good, FIRM foot pressure to engage each gear. If you don't engage firmly enough or the adjustment is out, then it will pop out of gear. You notice it more on the lower gears because the lower gears allow the engine to send more torque thru the clutch, thereby providing more force to make it pop out of gear.

If this doesn't help, then take it to a shop to see if it's simple worn clutch disks (easy to replace on this bike) or if the gears have worn teeth in the transmission.

Nov 05, 2013 | 1999 Yamaha V Star 1100 Custom

1 Answer

2005 flht wont shift into 1st


Hi Anonymous, it's either a clutch adjustment issue or a transmission shifting problem, shifter pawl, shifter cam or follower, shifter fork. The websites below will help guide you through these procedures:
How To Properly Adjust The Clutch Clutch Cable Harley Davidson
tony encalade harley trans shift cam avi
Good luck

Jul 29, 2012 | 2005 Harley Davidson FLHTC - FLHTCI...

1 Answer

I have a 2002 KTM 520 mxc. The bike started shifting hard as it warmed up. I replaced the clutch plates and springs with a Barnett digger kit. Bike shifts good now, but is slipping at higher RPMs.


The cable may be binding or the clutch adjustments may be wrong; there is normally two adjustments that have to be made if it is a cable style clutch.

1. the first adjustment will be on the engine near the clutch push rod and normally has a screw and locknut that is to be adjusted. Turn the handlebar adjustment first all the way in so that the cable has a lot of slack in it. Untighten the lock nut from the lower engine adjustment screw so that it does not interfere with the adjustment screw moving. Turn the screw inward until a very light tension is felt on the screw, then back it out about an 1/8 inch or so. tighten the lock nut back down and see if the locknut and screw together will rotate about 5-10 degrees when turned (this adjustment must not be so tight that it can not rotate when checked or it could cause clutch slipping so make sure that the adjustment screw rotates some after the locknut is tightened.

2. The final clutch adjustment is made at the handlebar. Turn the adjustment screw on the handlebar out until the clutch lever has about 1/8 inch of movement (before any tension is felt on the clutch lever) when the clutch lever is first being squeezed. Do not make the 2nd adjustment without any slack in the cable or the clutch may also slip.

If this is a hydraulic clutch and it slips at high rpm, the clutches could be getting hot, the springs are wrong for the clutch, or the clutch and steel fibers have the wrong installed height for the clutch hub (check the original clutch fibers and steels against the new ones installed and see that they are the same thickness or look up that fiber/steel thickness in a service manual).

Jul 23, 2012 | KTM MXC 520 Racing Motorcycles

2 Answers

Clutch is slipping on my 2008 flhx how do [ adjust clutch beyond adjustment in cable


take all slack out of cable . take derby cover off loosin lock nut in center if pack tighten addj screw turn in till seats back out 1/2 to 1 turn tighten lock nut . take slack out of cable . hatleytalking.con ...good luck

Oct 29, 2011 | 2008 Harley Davidson FLHX Street Glide

1 Answer

When shifting my 2005 flhtp seem like it clunks when going into gear upshift and downshift is that normal or do i need clutch adjustment


I'd adjust the clutch. With the engine off, put the transmission in first gear. Pull the clutch in and hold it. Try to start the engine. If the bike pulls forward, you need to adjust the clutch.

Find the rubber boot that covers the cable adjuster on the clutch cable and move it up or down. Loosen the lock nut and turn the adjuster inwards getting as much slack in the cable as possible.

Then, take the derby cover off the primary. You'll see an adjuster screw in the middle of the clutch assembly. Loosen the lock nut and turn the adjuster inwards until you feel a resistance. DO NOT FORCE THE SCREW OR YOU'LL DAMAGE YOUR INNER CLUTCH HUB. Turn the screw in until you feel a resistance. Then, back it back out 1/2 turn and tighten the lock nut. Replace the derby cover.

Go back to the cable adjuster and turn the adjuster barrel out until you have about 1/8 inch of freeplay in the cable. Tighten the lock nut and replace the rubber boot.

Good Luck
Steve

Jun 04, 2011 | 2005 Harley Davidson FLHTC - FLHTCI...

1 Answer

How do you adjust the clutch. Mine doesn't completely disengage when I shift gears. Too much play in the clutch handle.


You need to adjust the clutch cable adjustment for the clutch handle, THEN adjust the clutch itself.

1.First go to the clutch cable. Halfway down the cable is a rubber boot. Pull the rubber boot up the cable, (Or down. Pull it. Do NOT push), until it clears the adjustment. (The adjustment is a hex shaped piece, that is made of two parts. It's called a Barrel)
Use a 9/16 inch open end wrench, and a 1/2 inch open end wrench. Loosen the lock nut until you have around 1/16th to 1/8th of an inch clearance, of slack in the handle.
(Where the clutch lever, touches the clutch lever mount on the handlebars)

2.Now open the derby cover.
(The round cover on the back of your primary cover. Not to insult your intelligence. This -> https://www.denniskirk.com/jsp/product_catalog/Product.jsp?skuId=02649&store=&catId=&productId=p02649&leafCatId=&mmyId=
<-shows a custom primary inner, and outer cover. The derby cover is the round cover all the way to the right, on this custom primary cover. You can click on the photo to enlarge)

You will then see a single threaded stud, (Adjuster screw), in the middle of the clutch pressure plate.
This adjuster screw has a nut on it, to lock the screw from turning. (Jam nut)
Hold the stud end,(adjuster screw). from turning with a large flat tip screwdriver,
(May have changed to a small square end, that you use an open end wrench on), loosen the jam nut with an open end wrench.

Turn the adjuster screw in, until there is 1/8th inch slack of the clutch lever, to the clutch lever mount.
(The clutch lever mount is the part that attaches to the handlebars. The clutch lever is the part you squeeze in with your hand. The slack is the small space in-between the clutch lever, where it touches the clutch lever mount)

Now turn the adjuster screw out 1/2 turn. Tighten the jam nut. (Make sure you hold the adjuster screw in that place you set, as you tighten the jam nut. DON'T let the adjuster screw turn as you tighten the jam nut!)

3.Now tighten the lock nut, (Jam nut), on the adjustment barrel for the clutch cable. You should grease the threads of this adjustment barrel to prevent corrosion in the future. Pull the rubber boot back into place.

4.Replace the derby cover gasket as these will leak like a sieve. Replacing this gasket is cheap insurance. Install the derby cover, tighten the derby cover screws evenly. (Go to one screw, tighten until it touches. Then go to another screw, and do the same. After all three are touching, snug them down one turn at a time, going from screw to screw)

This is a thin cover. If you don't tighten the screws evenly, you can cause this thin cover to warp, and be the cause of a constant annoying oil drip.

Jul 13, 2009 | 2002 Harley Davidson FXD Dyna Super Glide

1 Answer

Have taken clutch apart and refitted, but is now slipping any help really aopopreciated thank you


hopefully you soaked your clutch plates in oil before installing them! If so adjustment is performed by loosening the jam nut on your clutch cable and running in the adjuster until you have enough slack to pull the clutch lever to the grip without any resistance. pull your derby cover off your primary cover and in the center of the clutch assembly you will see a threaded hex screw and a jam nut. loosen this jam nut enough to run the hex bolt in. tighten this hex bolt untill it just hits resistance and then back it off one half turn. Tighten the jam nut. reinstall the derby cover and adjust the clutch cable back out untill there is one sixteenth inch slack in it. Operate the clutch lever several times to reset the ramps then ride

Jul 09, 2009 | 2006 Harley Davidson FXDBI Street Bob

3 Answers

Adjust clutch cable


If you have a stock cable you need a 9/16 and a 1/2 in. wrench. about 1/2 way downn the cable there is a rubber boot. pull the rubber boot over the adjustment. Loosen the liock nut and adjust the cable so you have aprox 1/8 to 1/16 in. slack in the handle. Re tighten the lock nut and pull the rubber back over the adjustment.

Nov 10, 2008 | 2005 Harley Davidson FLHTC - FLHTCI...

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