Question about 2000 Harley Davidson XL 1200 C Sportster Custom
Posted by Anonymous on
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Posted on May 24, 2015
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Posted on Jan 02, 2017
If your engine is running with the clutch out and you pull in the clutch and put the transmission in first gear, you'll hear a clunk, this is normal. The reason is that although your transmission is a constant mesh transmission it is not a synchronized transmission. I don't know of any motorcycle that has synchronizers in the transmission. When the engine is idling in neutral with the clutch out, the gears and shafts in the transmission are spinning. When you pull the clutch in, wait a second or two for the spinning transmission components to slow down or stop spinning before you kick the transmission into low gear. The hotter the transmission is, the thinner the lubricant in it and the longer you need to wait.
A clunk is normal but if the bike trys to pull forward and you have to hold the front brake to keep the bike from moving or you cannot find neutral with the engine running, you need to adjust the clutch. To adjust the clutch, find the rubber bellows in the middle of the clutch cable. Slide the bellows up and break the locknut loose. Shorten the cable as much as possible. Remove the derby cover from the left side of the primary cover. In the center of the clutch assembly, you'll see a clutch release rod adjustment. Break the locknut loose and adjust the center bolt inwards until a resistance is felt. Do not force the bolt, just until a resistance is felt. Back off on the bolt 1/2 to 1 full turn and lock the nut. Replace the derby cover and adjust the cable so that you've vote about an 1/8 inch of freeplay at the clutch lever. Lock the lock nut and replace the bellows. Good Luck, Steve
Posted on Apr 28, 2010
SOURCE: six gear on my 2007
Adjust the clutch and see if it helps. Find the cable adjuster in the clutch cable and move the rubber boot up or down. Loosen the lock nut and turn the cable adjuster in to get as much slack in the cable as possible. Then, take the derby cover off. In the middle of the clutch is the clutch adjuster. Loosen the lock nut and turn the adjuster screw inwards until you feel a resistance. Do not force the screw or you'll bust your inner clutch hub. Back the screw off and turn it in several times to get the feel of it. Turn it in until you feel the resistance and then back off 1/2 turn. Tighten the lock nut and replace the derby cover. Then go back to the cable adjuster and turn the adjuster barrel outwards until you have about an 1/8 inch of freeplay. Tighten the lock nut and replace the rubber boot. See if that will help your problem. The gears cannot slip as your transmission is a constant mesh type design.
Posted on May 30, 2011
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