Question about 2000 Harley Davidson XL 1200 C Sportster Custom

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Oil is coming out the clutch cable at adjusting threads what would cause this

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Right where the threaded adjuster goes into the outer primary case, there's a locknut. There should be an O-ring on this treaded piece to seal in the oil. To replace the o-ring, you must go through the procedure to replace the clutch cable by removing the primary outer cover, disassembling the clutch release mechanism, and turning the cable out.

Good Luck
Steve

Posted on Aug 31, 2010

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1 Answer

How do I adjust the clutch?


loosen adjuster on clutch cable if thats your setup so lever has tons of freeplay acess the clutch adjusting screw and jam nut loosen jam nut some models have reverse threads turn in adjusting screw until it bottoms out on clutch pack then back it out one full turn then secure jam nut while holding adjusting screw in its set position replace covers replace any lost oil then go back to cluth cable adjuster extend it so while you are pulling slightly on cable with one hand check lever freeplay with the other you want about 1/8" of free play between lever and bracket then tighten its jam nut. this is also a great time to lube said cable i like the liquid graphite my self and a tad of grease or antisieze on the last inch or of the steel braided portion that comes out of the cable housing and into the lever since this is where they break 99% of the time good luck

Mar 15, 2015 | Motorcycles

1 Answer

Clucth adjustment


One thing that causes the clutch to slip is overfilling the gearbox. The level should be at the BOTTOM of the filler hole threads. More than that can cause oil to run down the clutch release rod. Once it is oil soaked, there is little you can do.

Dec 28, 2013 | 2001 BMW R 1200 C

2 Answers

Nutural is very hard to find on my harley 1999 flhtcui


The guy talking about the kind of oil to put in your Harley is brain dead. Dont listen to him an ruin your bike. Best thing to do is call a Harley dealership an talk to them about the kind of oil to use. Im not going to give you my two cents worth but dont ruin your Harley listing to that dummy he knos nothing. Never put car oil in a HARLEY

Aug 27, 2012 | Motorcycles

2 Answers

Recently, it has become hard to downshift my 2006 VTX1300R. Also difficult to get into neutral? Adjust clutch cable?


If you are using an automotive oil , it may be causing the issue. You can use any oil that is JASO MA certified motorcycle oil. 10w-40 for cold climate. 20w-50 for warm climate/touring. Car oils use different additives and may cause scoring in certain types of cam bearings. Do not use any oil that says " Energy Conserving " on the label . It will shorten the life of your wet clutch and transmission gears. If you choose Synthetic oils, they will help your bike run cooler and shift easier. At 1300 km you should have no problem switching over to full synthetic motor oil. I drive a 1976 GL1000 Goldwing and have similar shifting problems unless I use a full synthetic motorcycle oil . The problem is most noticeable in hot weather and just after getting off the freeway and onto city streets. Normal clutch problems on a cable clutch would be slippage caused by a binding cable, a worn clutch, or a cable set too tight.

Jan 15, 2011 | 2006 Honda VTX 1300 S

1 Answer

Broach slippage while in operation


You must check your oil level , and adjust catble length, if cable has no more adjustment ? You will
have to have a new clutch, about 35,000 to 40,000 miles on this clutch is worn out, and possible if
hard use at 23,000 miles. If less than these miles ? You should still have adjustment left. Make
sure linkage rod is not bent or bad threads, if this is the case, make sure you replace, because out
of adjustment will cause severe damage to your clutch . Ok

Nov 26, 2010 | 2007 Bajaj Platina

1 Answer

Replaced clutch, oil, cables...1998 electra glide classic..bike is hard to get into neutral once it is warmed up..


Make sure you do not overfill the primary. when putting the oil in the primary, have the bikes standing as straight up as possible. Add oil only until it comes to the bottom of the clutch spring. If you put too much oil in the primary, the oil will get in between the plates when the clutch is released and act like the oil in a automatic transmission torque converter. It will continue to drive just enough so that you cannot find neutral with the engine running.

Otherwise, you must make sure all clutch adjustments are correct. Loosen clutch cable all the way. Adjust clutch release adjuster behind derby cover, all the way in and back off one half to one complete turn, readjust cable for 1/8" freeplay.

Mar 12, 2010 | 2003 Harley Davidson FLHTC Electra Glide...

1 Answer

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.

Oct 26, 2009 | 1979 Harley Davidson XLH 1000 Sportster

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

3 Answers

Clutch isnt fully engaging


pls put in engine oil relief from friction

Jul 08, 2009 | 2003 Yamaha YZ 250

1 Answer

1997 Honda Magna VF45c 750 clutch adjustment


Did you do an oil change recently? Sometimes a motor cycles clutch shares the oil with the engine and a different kind of oil then the bike requires will cause the clutch to slip. This happens alot especially if someone switches to some types of synthetic oil when the bike had regular oil before the oil change.

Jun 23, 2009 | 1997 Honda VF 750 C Magna

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