Question about 2003 Harley Davidson XL 1200 S Sportster Sport

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I have to put a new clutch lever on my 2009 sportster xl 1200 the one on there broke off when the bike fell over.

Posted by Anonymous on

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  • Harley Davidson Master
  • 3,506 Answers

You will need to loosen the cable adjustment off all the way. Then you will need to remove the snap ring and pull the pin out and then pull the handle off and remove the nylon pin to release the cable from the handle and do not drop any of these parts and then put the new lever on, reinstall the parts in the reverse order and adjust the cable so there is 1/16 to 1/8 inch freeplay at the cable and perch area.

Posted on Nov 09, 2014

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Posted on Jan 02, 2017

v2iper
  • 150 Answers

SOURCE: harley sportster clutch

You just need to adjust your clutch cable.

Posted on Jun 27, 2009

wd4ity
  • 4565 Answers

SOURCE: 2003 Harley Davidson XL 1200 C Sportster Custom

I would guess stale gasoline or fuel. Try fresh fuel in the tank. If this doesn't clear the problem, you could need to have your carburetor or fuel injection system cleaned. I'm not even sure if they put fuel injection on Sportsters since I don't work on fuel injected bikes. I mostly work on the older bikes like Panheads, Shovelheads, Evos. Not too many Sportsters but have worked on a lot of Ironhead Sportsters. Try the fuel first. It's a cheap fix. Hope it works for you. Good luck with the knee replacement. My wife had one knee replaced and it works great.

Posted on Dec 15, 2009

wd4ity
  • 4565 Answers

SOURCE: Easy steps for replacing clutch lever? -Mark

Follow the clutch cable downward until you get to the rubber bellows that covers the clutch cable adjuster. Slide the bellows up or down to gain access to the adjuster. Loosen the lock nut and turn the adjuster inwards making the cable as short as possible.

Remove the pivot pin for the lever and rotate the lever forward. Positon the lever so that it will come off the cable end. Lubricate the cable end and replace the lever with the new one. Reposition the lever and install the pivot pin. Readjust the cable adjuster so that you have approximately 1/8" of free travel in the lever.

Good Luck
Steve

Posted on Jun 18, 2010

johnamyx
  • 108 Answers

SOURCE: i need to adjust my clutch cable on a 1994 1200

That is not a difficult task. There is an adjustment on the cable at the front of the frame. This adjustment should be loosened up and the derby cover removed. After removing the derby cover (that is on the Primary on left side of bike) there is an adjustment screw on the clutch. It takes a allen wrench (dont remmember size) and an 11/16 wrench. Loosen the lock nut with the wrench and screw in the allen in about three turns. Then pull clutch lever all the way in and leave it there. Take the allen wrench and turn out the screw while watching the clutch lever when the lever comes all the way out and the screw tightens then turn it back in 1/2 of a turn and hold it with the allen wrench in that position while tightening the lock nut with the wrench. Then go to the cluctch lever and hold the cable tight looking at the gap between the end of the cable and the clutch lever housing there should only be 1/16 to 1/8 inch play there if there is more or less then adjust the cable at the cable adjustment on the front of frame of bike till you get that spec. A quick way to check the cable is use a nickel if it fits tight it is right. I hope this helps you.

Posted on Dec 06, 2010

wd4ity
  • 4565 Answers

SOURCE: i have a 2005 harley davidson sportster xl 1200

If the carb is adjusted correctly, the engine will not idle without the choke when cold. I will usually take at least 3 to 5 miles of riding to get the engine warm enough to idle by itself without the choke. If your bike is a full operating temperature, it should idle at about 1000 RPM. If it's idling higher than this, you need to slow it down a bit.

Remove the air filter cover and look at the top right side of the carb. You'll see a screw there . This is the throttle stop screw. Turn the screw counterclockwise to lower the idle speed to 1000 RPM or so. Blip the throttle and let it settle back to idle. Reset it if necessary. Once set, put the air cleaner cover hand on.

Posted on Mar 15, 2011

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Find the cable adjuster in the middle of the cable, loosen the lock nut, and turn the adjuster barrel inwards to get as much slack in the cable as possible. Take the E-clip off the bottom of the clutch lever pivot pin and remove the pin. Pull the lever out and disconnect the cable from the lever. Stand the bike straight up and drain the primary case. Down on the primary, take the round plate off to expose the clutch release mechanism. Disconnect the clutch cable from the link that connects to the release mechanism. Screw the end of the cable out of the primary case. Install in reverse order and readjust the cable. Add oil back to the primary case.

Good Luck
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Aug 05, 2011 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

I have a 2009 harley sportster 1200c can i change the derby cover with out removing the oil


Yes, although I don't work on the later model bikes, I do believe you can do this because you have to take the derby cover off to adjust the clutch and you don't have to drain the oil to do that.

Good Luck
steve

May 14, 2011 | 2009 Harley Davidson XL 1200C Sportster...

1 Answer

Easy steps for replacing clutch lever? -Mark


Follow the clutch cable downward until you get to the rubber bellows that covers the clutch cable adjuster. Slide the bellows up or down to gain access to the adjuster. Loosen the lock nut and turn the adjuster inwards making the cable as short as possible.

Remove the pivot pin for the lever and rotate the lever forward. Positon the lever so that it will come off the cable end. Lubricate the cable end and replace the lever with the new one. Reposition the lever and install the pivot pin. Readjust the cable adjuster so that you have approximately 1/8" of free travel in the lever.

Good Luck
Steve

Jun 18, 2010 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

I have a 2001 harley davidson 1200 sportster. while riding it,it


G'day mate , sounds like primary drive / clutch basket. to find where the fault is turn the engine OFF , put it into gear and spin the rear wheel either by pushing or suspend the rear wheel , where the noise of spinning stops thats where the break in drive will be , fixing it may be a whole diferent matter but hope its just simple like clutch adjustment, ( to tight holding basket open )

Mar 29, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

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My sporty 883 2007 don't start when pushed the start button, it has all lights good. I have to pull the clutch lever and starts inmediatly. What can i do?


Evidently, Harley has added a safety switch to the clutch lever. The starter will not activate until the clutch lever is pulled in. Since I don't have a schematic for a bike this late, I can't tell for certain but that would be my guess. The owner's manual should tell you this.

Oct 26, 2009 | 2006 Harley Davidson XL 1200 C Sportster...

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1994 sportster xl shifting problem


Make sure your cltuch is disengaging. With the motor full hot (ride it a good while), shut iff the engine, put it in first, pull in the clutch and try to roll the bike. It should roll as easily (or almost as easily) as it would in nuetral. If it resist, loosen the clutch adjustment so it has plenty of free play in the lever. Ride and see if that makes a difference. If not, most likely you have a bent shift fork or shif shaft. :(

Sep 11, 2009 | 2000 Harley Davidson XL 1200 S Sportster...

2 Answers

Clutch


Glider, had this post on clutch adjustment by the book... http://www.hdtalking.com/transmission_clutch_and_primary/853-clutch_adjustment_by_the_book.html Also go to the general maintenance info on Clutches…

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