Question about Harley Davidson FXD Dyna Super Glide Motorcycles

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Leaking oil out of the primary derby cover any suggestions

Its after market inferno derby cover with only two allen head nuts on the left side to tighten down how can i fix this problem

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Either try a new gasket or get the right derby cover

Posted on Jun 28, 2009


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1 Answer

How to adjust clutch 2013 harley davidson dyna street bob

Remove derby cover. Loosen nut with 3/4" wrench turn allen head treaded rod clockwise until it stops. Then turn it ccw 1/2 turn. Hold it in place while tightening nut. Replace cover.

Aug 24, 2013 | 1979 Harley Davidson XLH 1000 Sportster

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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

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How to adjust a clutch on a2005hd fatboy?

Take all the play off clutch lever using adjusting nuts under rubber boot on clutch cable remove derby cover on primary cover use allen wrench to hold push rod while loosing lock nut turn allen wrench clock wise on push rod until it just stops do not apply pressure you will bend push rod.then turn counter clock wise about half turn hold with allen wrench tighten lock nut . Adjust nuts on cable until; 1/8 inch play on clutch lever should be good to go .

Mar 23, 2011 | 2005 Harley Davidson FLSTF - FLSTFI Fat...

1 Answer

Looking for primary drain plug

the primary drain plug is located on the left side of the bike underneath the chrome primary cover.
if your looking at the derby cover (which is the round chrome cover with five little screws in it its just below and slightly to the rear. its a little Allen head that sits underneath but on the chrome cover. there is one Allen screw that faces out directly below the derby cover and just behind that there is the drain plug facing down. i hope this helps

Jan 28, 2011 | 2003 Harley Davidson FXSTDI Softail Deuce

1 Answer

I need to adjust my clutch cable on a 1994 1200 sportster harley,wont fully engage and hold bike while it is in gear

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.

Dec 06, 2010 | Harley Davidson XL 1200 C Sportster Custom...

2 Answers

2005 Harley Davidson FLHTCUI Electra Glide Ultra Classic clutch adjustment ?

To adjust the clutch, first find the clutch cable adjuster. It should be somewhere along the downtube of the frame in front of the engine. Slide the rubber bellows cover either up or down to expose the adjuster. Loosen the lock nut and turn the adjuster inwards shortening the cable as much as possible.

Remove the Derby cover from the primary cover. In the middle of the clutch assembly is an adjuster bolt and a lock nut. Loosen the lock nut and turn the adjust inwards until you feel a resistance. Don't not force the adjuster, go inwards until you feel the resistance of the throwout bearing on the other side. Try it a couple of times until you get the feel of it. Go inwards until you feel the resistance and then come back out 1/2 to 1 full turn. Lock the lock nut down and replace the derby cover.

Then go back to the cable aduster and and adjust the cable adjuster out until you have about an 1/8" freeplay at the lever. Lock that lock nut down and reposition the bellows cover.

Good Luck

Jul 21, 2010 | 2005 Harley Davidson FLHTCUI Electra Glide...

1 Answer

Ajust the clutch

follow the clutch cable down till you come to a rubber boot slide the boot up loosen the 9/16 jam nut and 1/2 nut then go down and remove clutch cover there is a 11/16 nut and an allen bolt hold the allen and loosen the nut then turn the allen in until it lightly seats then back out 1/2 to one full turn hold and tighten the 11/16 nut replace cover go to the cable and adjust the 1/2 nut until there is 1/16-1/8 in freeplay at the clutch lever pull lever in at least three times to seat the throw out bearing then tighten the 9/16 jam nut pull boot down test ride good luck

May 18, 2010 | 2004 Harley Davidson FLSTC - FLSTCI...

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 ->
<-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

I would like to see exactly where you would adjust the clutch cable.demonstrate please.

Start at the clutch cable, loosen the locknut and screw the cable in so that there are no threads showing (till the adjuster touches the locknut.

You have to remove the derby cover (the big round cover with 5 screws on the outer primary) so the bike has to be sitting upright or the primary fluid will leak out.

Remove the derby cover, get an 11/16 (i think) socket and loosen the lock nut on the end of the clutch basket (use a hammer to tap the ratchet and loosen the nut).

Unsrew the nut a few turns and get an allen wrench (I forget what size but find one that will fit in the end of the rod that you just loosened up the nut on)

Using the allen key turn the rod in untill the clutch just start to engage, stop there then turn the allen 1/2 a turn out then using the ratchet and socket tighten the lock nut on the end of the clutch basket (tap the ratchet with a hammer to tighten so that the rod you just adjusted 1/2 a turn out does not move.

Now go back to the clutch cable and screw the cable back out so that you can see the clutch lever start to tighten up. Adjust the cable so that when you grab and pull the cable just before the lever you get a space just wide enough to slip a quarter into. So where the cable goes into the lever you want a little freeplay, the correct freeplay is 1/16 to 1/8, about the width of a quarter. Tighten the locknut on the clutch cable and put the derby cover back on.

Thats all there is to it, I hope this is clear enough, any questions just ask.

Here is the instructions from the manual:

1. Position motorcycle on a suitable lift, upright and level.
Point front wheel straight ahead.
2. Remove five TORX screws with captive washers to detach
clutch inspection cover from primary chaincase cover.
3. Remove and discard seal.
4. See Figure 1-20. Add free play to cable.
a. Slide rubber boot (1) off cable adjuster.
b. Holding cable adjuster (2) with 1/2 in. wrench, loosen
jam nut (3) using a 9/16 in. wrench.
c. Turn cable adjuster (2) until there is a large amount
of free play at clutch hand lever.
5. See Figure 1-21. Loosen jam nut (1) on clutch adjuster
screw (2). To take up all free play, turn screw inward
(clockwise) until lightly seated. Activate the clutch lever to
verify the balls are seated in the ramps.
6. Back out adjusting screw (counterclockwise) 1/2 to 1 full
turn.Tighten jamnut to 72-120 in-lbs (8.1-13.6 Nm), while
holding adjusting screw with an Allen wrench.
7. Squeeze clutch lever to maximum limit three times, to set
ball and ramp release mechanism.
8. Check free play.
a. Turn cable adjuster away from jam nut until slack is
eliminated at hand lever.
b. See Figure 1-22. Pull clutch cable ferrule (2) away
from clutch lever bracket (3) to check free play. Turn
cable adjuster as necessary to obtain 1/16-1/8
in. (1.6-3.2 mm) free play between end of cable ferrule
and clutch lever bracket.
9. Hold adjuster with 1/2 in. wrench. Using 9/16 in. wrench,
tighten jam nut against cable adjuster. Cover cable
adjuster mechanism with rubber boot.

10. Install clutch inspection cover and new seal as follows:
a. Thoroughly wipe all lubricant from cover mounting
surface and groove in chaincase.
b. Position new seal (1) in groove in primary chaincase
cover and press each of the nubs on seal into the
groove. The nubs will retain seal in position.
c. Insert screw (with captive washer) through clutch
inspection cover and carefully thread it into the top
cover screw hole.
d. Start the remaining four screws (with captive
e. Alternately tighten screws to 84-108 in-lbs (9.5-12.2
Nm) following torque sequence shown in Figure 1-23.

Jun 10, 2009 | 2008 Harley Davidson FLHRC Road King...

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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