Question about 2002 Harley Davidson XL Sportster 883

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Pulled cover off and cultch cable and now i have no clutch can some one help

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Well, let's try adjusting the cable. Find the clutch cable adjuster in the middle of the cable. Break the locknut loose and turn the adjuster inwards to get all the slack you an in the cable.

Now at the primary cover, remove the clutch release mechanism cover. Take the spring and the lock nut out of the cover. Now, turn the screwdriver slotted acrew counterclockwise until it stops. Then turn it clockwise 1/4 turn. Replace the lock nut, spring, and the cover on the primary.

Go back to the cable adjuster and adjust it outward until you have about an 1/8" freeplay at the lever.

Good Luck

Posted on Nov 12, 2010


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Clutch is slipping

The clutch friction plates may be worn out.

The clutch adjustment is likely way out in any case. You will need to go into the inspection (derby) cover and adjust the clutch and the cable adjustment will have to be done at the same time.

Slide the rubber cover off the cable adjuster. Then holding cable adjuster with a one half inch wrench, loosen the jam nut using a nine sixteenths 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 using a T27 TORX driver, remove the five TORX screws with washers to remove clutch inspection cover (derby cover) and seal in the primary cover (unless it has a gasket as aftermarket or Screaming Eagle covers will have in which case remove the gasket). IF the screws are very tight use a spring loaded impact driver with the correct T-27 TORX bit and a suitable sized hammer to shock them loose OR heat them with a hot air gun (sometimes people also put Loctite on the screw threads which then may need heat to break down this locking compound). THEN using an Allen key in, and to hold, the adjustment screw and a wrench on the locknut loosen the locknut and then turn the adjusting screw in or clockwise until resistance is felt (to take up all free play and lightly seat the adjuster to the clutch push rod but no more) and then activate the clutch lever to ensure that the clutch release balls are seated in the ramps. THEN back off the adjusting screw one half to one full turn. THEN holding the Allen key and adjusting screw so neither can move anymore tighten the locknut to 72-120 in-lbs (8.1-13.6 NM). THEN squeeze the clutch lever to maximum limit three times, to set the ball and ramp release mechanism. THEN replace the cover seal or gasket if it is very old, deteriorated or etc. and verify that the seal is fully seated in the groove of the cover and if there is a gasket make sure it is facing the correct way i.e. with the rubber sealing surface towards the primary cover and the triangulated screw hole to the top. THEN using the T-27 TORX driver, install the five 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 (9-12Nm). THEN move to the cable adjuster and 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 free play, so turn the cable adjuster as necessary to get this amount of free play 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 free play 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. These cable adjuster instructions are for stock HD clutch cables as aftermarket cables will be somewhat different to adjust BUT the idea will be the same.

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1 Answer

2004 1200c clutch adjustments

Hi Anonymous, spray some silicone or brake kleen at the top inside of the rubber boot covering cable adjuster and slide boot off the adjuster. Back off jam nut and screw adjuster in to give excessive freeplay at clutch lever. Remove left foot rest. Remove large round clutch inspection cover, being carfull not to dislodge large quad seal on primary cover. Remove spring and hex lock plate from adjusting screw. Turn adjusting screw counter clockwise until resistance is felt, then clockwise 1/4 turn. Re-install hex lock plate and spring and clutch inspection cover and footrest. Back out adjusting screw on cable so that while pulling the clutch lever with one hand and pulling the clutch cable with the other hand you achieve 1/16" to 1/8" free play. Tighten jam nut, slide rubber boot back over cable adjuster and your good to go. Good luck

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1 Answer

Adjust clutch on 06 flhrci

Loosen clutch cable (if not hydraulic clutch) completely (clutch cable adjustment is about 1/2 way down cable.
Remove derby cover on primary cover. Looks similar to this:

Loosen locknut on adjuster screw in center of clutch pressure plate:

Screw adjuster in until it JUST touches.
Back off 1/2 to 1 full turn.
Hold screw to prevent it turning while locknut is tightened.

Readjust clutch cable until it has about 1/16" to 1/8" free pay.

Measure by pulling cable away from clutch lever and check the gap:

Dec 31, 2013 | Harley Davidson Motorcycles

1 Answer

I got a 1998 Toyota corolla and my cultch is sometime all the way down to the floor and it wouldn't go into gear is it the transmission or the transmission fluid???

I would guess either damaged input shaft splines, or broken clutch springs. In a manual transmission the fluid does not affect the clutch.

May 10, 2013 | Cars & Trucks

1 Answer

Zx-9r 2000 how do you remove the clutch side cover to change the clutches

The clutch cover is removed in a two step process.
  • Remove the clutch cable by loosening the adjustment at top and bottom first. Then remove the cable end from the clutch lever. This should give enough slack to remove the cable at the bottom by the clutch cover. ** Take notice of the angle of the lever that the cable goes into the cover. You will want to re-assemble the clutch cover with that lever in the same angle.
  • Remove the clutch cover bolts around the outside of the cover.the cover should now be removed by pulling the cover straight out.

Thanks and I hope that this helps.

Jan 21, 2011 | kawasaki ZX-9R Motorcycles

1 Answer

My clutch is not catching when I pull the lever it does not stop , it keeps pulling. What can I do to fix this? can I adjust the clutch behind the cover somehow?

you can adjust the tension on the cable, if that dosnt help the yz had a problem with their clutch springs. driain the oil, shut the gas off and lay the bike down on its left side so the clutch cover is facing up. pull the clutch cover off. go to home depot and but a package of 6mm washers. take the 5 or 6 (cant remember how many there are) screws out that have the springs under them, but a washer on the screw and but it back on. the washer will fall into the spring, this is ok.. do that to all 6, but the cover back on and add 650cc of oil. This will help a ton, if not you need new clutches...

Jun 26, 2010 | 2003 Yamaha YZ 125

1 Answer

Bought a used 88 cr250 and like and idiot i didnt ride it first to make sure the tranny shifted properly...well, it didnt. when i pull in on the clutch to drop the bike in gear with the motor running it...

sounds like you need a clutch. Yes the friction plates should move a bit when you pull your clutch lever in that is how the clutch works what oil are you running in you tranny and have you tried adjusting the clutch cable? When you had your clutch apart what did the friction plates look like was there much meat left on them?

Oct 03, 2009 | 2005 kawasaki KX 250

1 Answer

Have taken clutch apart and refitted, but is now slipping any help really aopopreciated thank you

hopefully you soaked your clutch plates in oil before installing them! If so adjustment is performed by loosening the jam nut on your clutch cable and running in the adjuster until you have enough slack to pull the clutch lever to the grip without any resistance. pull your derby cover off your primary cover and in the center of the clutch assembly you will see a threaded hex screw and a jam nut. loosen this jam nut enough to run the hex bolt in. tighten this hex bolt untill it just hits resistance and then back it off one half turn. Tighten the jam nut. reinstall the derby cover and adjust the clutch cable back out untill there is one sixteenth inch slack in it. Operate the clutch lever several times to reset the ramps then ride

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