Question about Harley Davidson Road Tech HA90 MP3 Player

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Clutch cable 05 road king noticed today that the clutch cable where it connects to the clutch lever has about a quarter inch of play at the ferrule (believe i spelled that right) is that too much play and how do i determine proper adjustment?

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  • bearpaco May 31, 2008

    thank u very much for the rapid response at the risk of sounding ignorant i take that play out with the adjustment in the middle of the cable correct?

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To determine the actuall adjustment to the clutch lever run ur machine as normal on the 2nd gear and then reduce the speed teh gear will slip tightn up the lever till tht play goes away ..and do let me know

Posted on May 31, 2008

  • varun grover Jun 01, 2008

    yes but be care full even doing tht even after tighting up quite bit if it slips again then might be clutches are worn so chk those aslo

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How to adjust the clutch on a 2003 sportster 883 custom


Slide the rubber cover off the cable adjuster. Then holding cable adjuster with 1/2 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).

Aug 06, 2014 | Motorcycles

1 Answer

Bike is not idling, wants to keep creeping while clutch is in and brake is on, had hard time today going into neutral


You're clutch cable needs to be adjusted. Most likely you can gain enough "pull" up at the hand lever. The adjustment will be turned clock wise, your goal is to imagine you're pulling the inside cable more-farther to dis engage the engine from the wheel. You should have a little play when the lever is at rest to be absolutely sure it's completely free. Might be worth a couple bucks to have a shop do it and ask to watch. It's a quick, easy adjustment but should have an experienced hand.

Jul 18, 2014 | 2011 Harley Davidson FLHRC Road King...

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

Clutch adjustment


Slide the rubber cover off the cable adjuster. Then holding cable adjuster with 1/2 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 using a T-27 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 freeplay and lightly seat the adjuster to the clutch pushrod 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 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). 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.

Jul 06, 2014 | Harley Davidson FLHRI Road King...

1 Answer

My clutch so how do i properly adjust the clutch on 07 h.d. xl 1200 sporty-youttube


Slide the rubber cover off the cable adjuster. Then holding cable adjuster with 1/2 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).

Jun 28, 2014 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

How do i ajust the clutch ?


Slide the rubber cover off the cable adjuster. Then holding cable adjuster with 1/2 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 using a T-27 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 freeplay and lightly seat the adjuster to the clutch pushrod 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 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). 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.

Jun 20, 2014 | 2002 Harley Davidson FLHR - FLHRCI Road...

1 Answer

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.

May 25, 2014 | Harley Davidson FLSTC Heritage Softail...

1 Answer

Hard to put into neutral when running , any clues


Bike usually show the symptom of not being able to find neutral when the clutch is either not adjusted correctly or the clutch pack is warped. Make sure your clutch lever doesn't have excessive free play. If you pull the cable out of the housing with a little pressure ( but not pulling it out all the way ) you shouldn't have more than the thickness of a quarter between the cable ferrule and the bracket.

Nov 02, 2013 | Benelli TnT 1130 Motorcycles

2 Answers

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

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
washers).
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...

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