Question about 2000 Harley Davidson XL Sportster 883

1 Answer

Clutch cable sportster

Need to remove clutch lever for replacement

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  • Harley Davidson Master
  • 1,554 Answers

Look on the underside of the clutch perch (mount).
There's an "E" clip on the end of the pivot pin.

http://lackof.org/taggart/hacking/supermicro-fan/e-clip.jpg

Remove this clip, and you can push pivot pin up and out of the clutch lever/mounting.

Posted on Apr 12, 2014

6 Suggested Answers

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  • 2 Answers

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Posted on Jan 02, 2017

OneRide
  • 379 Answers

SOURCE: Clutch not fully disengaged, hard shifting - 96 FLHTCU

If the previous solution doesn't fix it, beg, borrow or steal (maybe even BUY) a service manual and run thru the clutch adjustment BY THE BOOK.. I also would suggest removing the clutch cable and checking for binding, fraying, kinks, etc. If the problems still persist, total disassembly and inspection of the clutch will have to be done.

Posted on Jun 04, 2009

  • 233 Answers

SOURCE: how do I disconnect the clutch cable on my 2000 sportster.

relieve the pressure on it by loosening the nut below the handle on the cable, (use a back up wrench) that will allow the cable to be removed from the keeper on the engine side

Posted on Jul 12, 2009

wd4ity
  • 4565 Answers

SOURCE: Need to replace clutch cable on a 2002 H-D Dyna,

To replace the cable, you are going to have to remove the cover on the end of the right side of the transmission. Just follow the cable and see where it goes into transmission. You may have to remove exhaust pipes to do this. The threaded cable end screws into this cover. If the handlebars are the stock type bars, simply replace with a stock cable. If the bars have been changed, you'll have to match the overall cable length to get the right cable.

Posted on Sep 24, 2009

wd4ity
  • 4565 Answers

SOURCE: clutch cable broke at handle lever on 1979 harley davidson sporst

To change the clutch cable on you '79 Sporty, you'll have to take the outer primary cover off. To do this, you'll have to drain the oil from the primary, take the left side foot peg off, and loosen the primary chain adjuster on the bottom side of the primary. Loosen the locknut and use an allen wrench or hex key to screw the adjuster bolt downward.

If you need to know anything else, drop me a line at wd4ity@bellsouth.net

Then, remove the large "plug" towards the rear of the cover. Inside, you'll see something that looks like a nut but with no threads in it held in by a small spring. This the the lock nut, remove it. Below it is what looks like another nut with a slotted adjuster bolt sticking out. Remover the bolts from around the primary cover and break it loose from the engine. While turning the adjuster screw at the rear of the cover inward, remove the cover.

The cable connects to the cluch release mechanism. By turning the "link" downwards, you can disconnect it from the mechanism. Notice which way the "link" in attached to the release mechanism. Take the "link" off the end of the clutch cable.

Break the lock nut loose at the threaded cable adjuster on the outside of the case and screw the adjuster all the way out of the primary cover. Disconnect the cable at the handlebar lever and your cable is out.

Reinstall the new cable in the reverse order. When replacing the outer primary cover, make sure you use a new gasket on the cover as well as on the foot peg boss. The "foot peg boss gasket" is very important. You'll see an aluminum boss with a threaded rod sticking out of it that holds your left foot peg on. There is a round gasket that goes over this threaded rod and seals against the boss. If you leave this off, your bike will leak oil around this threaded rod when your foot peg goes on. Make sure you specifically ask for the "foot peg boss gasket" when you buy the new primary gasket. It's just a round gasket a bit larger than a quarter.

As you put the primary cover back on, there is a spring on the primary chain adjuster. Part of the spring is in the primary cover and the other part is in the engine. You'll see how it goes in. There is a large stud in that area that the outer primary cover slides up on. Adjust the tension on the primary chain by removing the "plug" at the top of the primary cover. You want 3/4" to 7/8" up and down play in the chain with the engine cold.

On the adjuster, as you're installing the outer cover, turn the ajuster screw back into the clutch release mechanism by turning the screw backwards. Once you have the outer primary cover completely installed, you must adjust the release mechanism. Adjust the screw inwards until you feel a resistance, then back the screw off about a 1/4 to 1/2 turn, insert the "lock nut" and spring, and install the "plug". Then, using the cable adjuster on the outside of the cover, adjust the cable. Add oil.

Posted on Oct 26, 2009

  • 15 Answers

SOURCE: how to remove the clutch cable from the primary on

Got to take the cover off and disconnect the cable inside and then you can unscrew it from the case. Not real hard

Posted on Apr 09, 2010

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1 Answer

How do i replace a starter on a 2005 harley 1200 sportster


Disconnect the battery and then the wires on the charger. Drain the transmission (left cover). After that, you can remove the shift lever connection and the clutch cover. Disconnect the clutch cable from the clutch assembly. Now you can remove your complete primary cover. After all that you will want to remove the two screws that hold the starter to the engine. Then simply put everything back in the reverser order using all new gaskets and seals and fill the transmission back up w/the proper amount and weight of oil.

Mar 07, 2015 | 2005 Harley Davidson XL 1200 C Sportster...

1 Answer

How do i adjust my clutch on my 2003 1200c sportster


Slide the rubber cover off the cable adjuster. Then holding cable adjuster with one half inch wrench, loosen the jam





nut using a 9/16 inch wrench and back the jam nut away from the cable adjuster and then move the adjuster toward jam nut to introduce a large amount of free play at hand lever. THEN remove the locknut and bolt to free the left side footrest from the footrest support and then remove the footrest and spring washer and THEN using a T-27 TORX driver, remove the four TORX screws with washers to remove clutch inspection cover exercising caution to avoid damaging or dislodging the quad ring in the primary cover. THEN slide the spring with the attached hex lockplate from the flats of the adjusting screw. THEN turn the adjusting screw counterclockwise until resistance is felt THEN back off the adjusting screw 1/4 turn. THEN slide spring with hex lockplate onto the flats of the adjusting screw and if necessary, turn adjusting screw clockwise just slightly so that the lockplate slides onto the flats while also fitting within recess of the outer ramp. Replace the quad ring if it is very old, deteriorated or etc. and verify that quad ring is fully seated in the groove of the primary cover and a few well spaced drops of instant contact cement can be used to hold it in place. Using the T-27 TORX driver, install the TORX screws and washers to secure the clutch inspection cover in place and tighten the screws in a crosswise pattern to 84-108 in-lbs (9-12





Nm). THEN turn the cable adjuster clockwise away from the jam nut until all of the slack is eliminated. THEN pull the clutch cable ferrule at the hand control end of the clutch cable at the hand control lever bracket away from the clutch hand lever bracket to check the free play. You need to obtain 1/16 to 1/8 inch free play between the end of the cable ferrule and the clutch hand lever bracket i.e. while you are pulling the cable away from the clutch lever mechanism bracket there should be a space or freeplay of 1/16 to 1/8 inch or in other words if you can pull the clutch cable away from the clutch lever bracket that much you have the correct lever freeplay, so turn the cable adjuster as necessary to get this amount of freeplay between the end of the clutch cable and the clutch lever bracket on the handlebars. After you have adjusted the cable so that you have this freeplay then hold the adjuster with a 1/2 inch wrench and using a 9/16 inch wrench, tighten jam nut against cable adjuster and then pull the rubber cable adjuster cover over the cable adjuster mechanism. THEN place the spring washer over the lower inside hole of the left footrest support with the concave side of the spring washer facing the support flange. THEN align the holes in the footrest with the threaded holes in the support and spring washer and install the bolt and





Locknut and tighten the locknut to 96-192 in-lbs (11-22 Nm).

Jul 11, 2014 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

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.


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.

Oct 11, 2013 | 2003 Harley Davidson XL 1200 S Sportster...

1 Answer

Brake levers replacement


Hi Anonymous, for more information about your question please visit the website below. Good luck and have nice day.
Delboy Garage Harley Sportster Brake Lever change
Delboy Garage Harley Sportster Clutch Lever change

Mar 04, 2013 | 2005 Harley Davidson FXSTD - FXSTDI...

1 Answer

Clutch lever is not working pulls in very easy but doesnt ingage my clutch 2005 harley sportster 1200c


Hi Kelly, for more information about your question please visit the websites below. Good luck and have nice day.
Sportster Clutch Cable Replace

Jul 27, 2012 | 2000 Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to adjust the clutch on 1988 sportster


Ok let me attempt this. I'm on my iPhone lol. You will need a 1/2 and 9/16 wrenches T27 bit and a small screwdriver.
1. Looses the clutch cable all the way using your wrenches
2. Remove the clutch inspection cover on the left side of bike
3. Remove the center retainer and spring from clutch
4. The center screw Is reverse thread so go clockwise to loosen it. Just loosen it a few turns.
5. At this point I lube up the cable and move the lever in and out
6. Go back to the center screw and tighten it to the point where the lever moves a little. But more important you wanna watch the plate you screwing just touches the clip once you get a feel for it and the plate is just touching back off the screw 1/2 turn and replace the retainer and spring and you can put the cover back on
7. Next adjust the cable until you can see the lever move. Keep adjusting until there is about 1/4 to 1/2 inch Freeplay measured between the front of the lever and the housing

Email back if you need more info. I don't have a sporty in the shop to take pictures. But I van clarify by email if needed

Oct 27, 2011 | 1993 Harley Davidson XLH Sportster 883

1 Answer

Details on removing the clutch cable from a 2005 harley sportster 883 XL custom


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
Steve

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

2 Answers

Need clutch rod adjustment


Slide the rubber boot away from the clutch cable adjuster.
Loosen the cable locknut and turn the adjuster to provide as much cable slack at the clutch lever as possible.
Support the bike so that it's sits straight up.
Remove the clutch inspection cover.
Slide the spring with the attached lockplate off of the adjusting screw flats.
Turn the clutch adjusting screw counterclockwise until the screw stops. Then turn the clutch adjusting screw clockwise 1/4 turn.
Install the lockplate and spring onto the adjuster screw flats. You may have to turn the adjuster slightly to get the lockplate to line up.
Reinstall the clutch inspection cover and O-ring.
Adust the clutch cable at the cable adjuster all the way out and work the clutch a time or two. Now adjust the cable so that you have between 1/16" and 1/8" of freeplay at the clutch lever.
Tighten the cable adjuster locknut and replace rubber boot.
Good Luck

Mar 28, 2010 | 1993 Harley Davidson XLH Sportster 883

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