Delboy's Garage, Harley Sportster Clutch Adjustment.

[roleeesh]

hi moonfleet41. great videos, they are a lot of help. one question - would i do anything different to change the clutch cable? putting different bars with an extended cable on and dont want to mess it up. any help appreciated. thanks!

[Moonfleet41]

@roleeesh Hi mate, and thanks for your kind comments. no you can just follow the same steps to change the cable.. open the primary outer plate, you'll see the cable hooked into the clevis on the clutch, just back all the slack right off on the cable, and remove the cable head from the lever at the top, this will give you enough slack to unhook the bottom.. then just back out the nut in the casing, job done, then just install the new one the same way... good luck with it, cheers. Del.

[roleeesh]

@Moonfleet41 cheers dude your a ledge! keep the vids coming 

[Moonfleet41]

@roleeesh No worries mate, let me know if you get stuck, which of course you wont, coz its a piece of p155 and yur a biker.... easy..!

[TheFirejacker]

VERY WELL EXPLAINED!! THANKS YOU SIR !! VERY BIG HELP

[Moonfleet41]

@TheFirejacker you are very welcome sir, its a pleasure to help, the main dealers do very little to help thier customers learn simple jobs like this, hell, i think they would even make money from running proper classes, but in my lifetime, i have never seen it once... maybe its more lucrative to just charge you a fee and hand you a coffee while you wait... take care.. Del.

[Moonfleet41]

@TheNamehere21 Thank you for your kind comments... and you're most welcome, im glad the video helped you out... its nice to be reasured when you aren't sure on something.. Checked out your video... thats a stunning sportster you have there. i love Rainbow Flake paint, and so much chrome, it must take hours to clean and keep lookin as good as that.. congratulations on a great custom.. you dont see them that good often.. regards.. Del,.

[funknando007]

Great video! Thanks!!!

[Moonfleet41]

@funknando007 You're most welcome, i hope it helped you out.. Cheers, Del.

[Demonic87z]

Great Video, you explain everything very well. I will be doing this in the next couple days.

Thank You for posting!

[Moonfleet41]

@Demonic87z Hi mate, thank you for the kind comment.. i wanted to make it all clear because the single biggest mistake with that adjustment is that folks adjust it the wrong way round and then cant fathom out why it wont go into gear.... good luck with the task mate, take your time its a piece of cake.. regards. De.

[LTSpenny]

Thanks for the how to! Was kind of weary of the job but after seeing you do it it's so easy! Thanks again!

[Moonfleet41]

@LTSpenny You're more than welcome buddy, its the way with so many jobs on Harleys, they are a simple and incomplexed bike, its just the natural fear of the unknown and making a mistake that may cost you more money.. Glad it helps, thats exactly what its for.. Ride Safe.. Del.

[droid740]

Clear, articulate, thoughtful, and like all good lessons, your passion carries us through. Had a great time watching. Cheers.

[Moonfleet41]

@droid740 Why thank you sir, you are too kind. i hope it helped you save a few beans by not paying the dealer to do such a simple job... take care.. Del.

[captainawesum1]

hi i followed what you did and the clutch still wont engage i recently change my bars there a different style but the dimensions were the same any ideas?

[Moonfleet41]

@captainawesum1 Hi there.. ok, so you say "the clutch wont engage", to you mean that it wont dissengage the gears, has too much slack, or does it go in gear without the clutch.. i can help if you could be a bit more specific.. cheers Del.

[okieriverboy]

Nice video. Added to my faves. Have two sporsters and videos like this one really does help with DIY maints. Keep them coming!

[Moonfleet41]

@okieriverboy Sure thing Okie, im always posting up some kind of how-to stuff most days...thanks for the kind comments buddy.. ride safe..del.

[mitchelljm1]

I like the video, been there, done that so I must add this. When the primary cover is off the oil level should be checked as well as the quality of the oil. Your's is newer so probably not anything abnormal there but for others it's a great habit to get into. maintpro@usa.com

[Moonfleet41]

@mitchelljm1 Wise words Mitch, always use every opportunity to make related checks while doing any work, but like you say, that oil was changed only a week before the video was made, and i knew it was fine... plus i wanted to keep the video focussed on just adjusting the clutch and nothing else.... thanks for your kind comments mate.. Del.

[Rasd4Metta]

Wow I'm learning so much about bikes! Your a great instructor!

[Moonfleet41]

@Rasd4Metta ha ha, listen to Mr Tech over there..lol..you are too kind. we'll have to swap knowledge buddy, you can teach me how to fit a Corvette motor into an old Muscle car so it looks like it was born there...."hide not thy light under a bushal brother.."...>;^-)

[Rasd4Metta]

@Moonfleet41 I'm tellin ya Del, I've been a tech for 12 yrs and never work on bikes before, you make it look so easy and I don't get sleepy watching you explane stuff. Some video's out there I'm out like a light lol

[Moonfleet41]

@Rasd4Metta Ha ha, there you go again, now ill need a larger crash helmet..DOH...lol. mind you, i beleive that the moment you think you have nothing to learn, you fail on all fronts, we never stop learning aye chap..

[Rasd4Metta]

@Moonfleet41 Oh I hear you there buddy! I'm kinda like you in a way, my dad tought me alot when I was young and now I'm teaching myself how to paint a car for the first time ever with the help of everybody on youtube!!!

[Moonfleet41]

@Rasd4Metta Same here, i have no kids to pass anything on to, so i do it here, that way knowledge lives on and guys save money, win win situation..not to mention the pride and self respect you have in doing something yourself.

[Rasd4Metta]

@Moonfleet41 Wow no kids either eh?

You got that right brother! When I was building my chevelle I had nobody to share the progress with and now with you tube people can enjoy and watch the hole process come together and the feed back is great cause it your doing something wrong they let you know before you get to far into it!

[cwrkrs]

cheers for the helpful videos this one and timing chain helped me out.

all the best.

[Moonfleet41]

@cwrkrs You're very welcome, im glad it worked for you, it really is a simple task, so often shrouded in mystery to keep you running to the dealer to spend your money.. Good luck.. Del.

[patricktatten]

An excellent video, nicely paced, and packed with practical, useful information.

Well done!

[Moonfleet41]

@patricktatten Why thanks Patrick, you are too kind, im glad you liked it and found it useful. knowledge is free mate, got to spread the love aye..  Ride safe.. Del.

[cl4yd0h]

Thanks a bunch, This helped after my clutch wire snapped on my XR. I was a little confused at adjusting the main screw and swear I messed something up because I couldn't get it to feel right! I pulled the whole primary cover to replace the gasket and there was some nasty foamy gunk in there I wanted to clean out. Anyways, I watched the video, went out, adjusted, sealed it up and test ride proves to be wonderful.

Really appreciate it!

[Moonfleet41]

@cl4yd0h You're more than welcome buddy, its a pleasure to be of help.. The design is a bit back-to-front in my opinion, doesnt follow mechanical logic, but thats harleys for yah, lol, and maybe thats why we like them aye.? The 'Foamy gunk' in your primo case was just condensatiion water that has imulsified with the oil, its quite natural and normal, wont do any harm as long as its cleaned out once a year or so.. Ride safe, Del.

[AsphaltCowboyPacks]

if the adjuster boot isnt tightly sealed you can get rain or water from washing inside the adjuster and it will run down thru the cable into the primary case NOT GOOD

[Moonfleet41]

@AsphaltCowboyPacks Never heard of that one before mate, the tiny amount or water that gets behind the rubber boot would never be enough to run inside the cable, plus the outer casing is bonded to the steel nut so the only route in to the inner wire, would be through the thread, and its locked against itself.... so its pretty impossible... however, like i said, squirt some WD40 inside the boot, and cable tie is top and bottom if you are worried..

[AsphaltCowboyPacks]

@Moonfleet41 actually it is entirely psble the boot can fill with water and then get through the threads and around the slip joint on the adjuster run through the cable and into the primary case. I've seen it happen on multiple harley's not only sporty's. Best defense is replacing that boot when you change the primary lube and throw a little vaseline inside each boot end, and oil the insider of the adjuster slip joint.

[AsphaltCowboyPacks]

@Moonfleet41 It's a few extra dollars but considering what a clutch, primary chain or gear box costs to replace it is pretty cheap. Take it from an American mate we know our Harley's.

[Moonfleet41]

@AsphaltCowboyPacks Had 8 Harleys and never seen that, but its good sound logic, nothing is infallible... i cable tie the rubber boot on mine top and bottom which seals them, and yeah, vasalene or grease the adjuster assembly too, good call... thanks fellah. every tip counts. Regards Del.

[syizm]

Well, turns out you were right about trying it with the engine running. I had assumed erroneously that putting it in first gear and holding the clutch in was a good way to check for proper adjustment, but it doesn't roll naturally that way.  However, once the engine was running everything worked just fine! Thanks again for the video and good advice.

[Moonfleet41]

@syizm Doh.! ha ha, thats how we learn brother, well done for getting it sorted out yourself. Now you have priceless knowledge of not only how to fit a new cable, but what to expect in its performance... Top man.. Del.

[syizm]

Thanks for all the help. The bike is a 2005 Sportster and I've serviced it with the factory primary chaincase/transmission lubricant. By plates do you mean the ramp assembly (piece with the three bearings inside that opens slightly when twisted?) - that piece is clean and free of debris. Bike operated just fine until I changed the cable yesterday. Hasn't really ever sat for long. I will make a video later if I can't figure it o ut.

[Moonfleet41]

@syizm sending you a PM...

[syizm]

Great video. Put in a new cable today (old one had small leak) and for the life of me can't get it to adjust properly. Followed this video exactly (as well as the FSM a dozen times) and best I can do is get the bike to drag really bad with it in gear. I haven't started it yet, but I'm testing it with the clutch in, in first gear, to see if I can get the bike to roll smooth... It will peg against the gear but roll with great effort, like the clutch is only half engaged.

[Moonfleet41]

@syizm Hey Buddy, sorry you are having trouble. Im assuming you have the middle cable adjuster opened up, and you didnt disturb the clutch pack? Its not easy to engage first and push the bike with the clutch in, if the bike has been sat for a long time the plates can get a bit glued together too. But the main thing is "Do you have tention in the cable, or is it still slack when adjusted right out?" if so, you may have the wrong cable buddy.check the part number with the dealer over the phone

[syizm]

@Moonfleet41 Allow me to clarify; I have adjusted the cable properly as per the FSM, your video and a few websites. I do this with the gearbox in neutral. I button up, roll the bike around in neutral, then push the clutch in and kick it in to first. Now, with the clutch in AND in first gear the bike should roll freely. However, it will "peg" against the gear and stop.  If I push really hard the bike will roll BUT NOT turn the engine, as if it's riding on the clutch.

[Moonfleet41]

@syizm yeah, it sounds like the plates are binding, if the clable is taught, and the pack is being pulled all the way open, yet it still binds.. then like i said, the plates are perhaps a bit gummed up and stuck together with the oil. is the oil old, the right kind?, its hard without opening the primary for a looksee.. have you tried engaging gear with the engine running yet,? pump the clutch lever in and out twenty or so times, then engage. it may break it free! worst it will do is stall.

[syizm]

@Moonfleet41 That is to say I believe that the clutch isn't releasing entirely. With the clutch handle released the bike will not roll at all in first gear regardless of how hard I push. (Of course it would eventually crank the engine in this case.) Again, adjusting as per FSM, clutch handle in, bike in first, it will "hit" the gear, then roll with great effort against the resistance of the clutch. The cable is correct; good P/N and I measured it against the one I removed. Cheers & thanks.

[Moonfleet41]

@syizm Tell you what, Im not so sure there wouldn't be some clutch plate interface even with it full open, the plates only separate by about 1/16th" at most, more like 1/32nd" if they are a bit old and have some heat warpage.im gonna slip mine in gear when i get home in about 3 hours, and see if i can push mine with the clutch in while in 1st, (all Sportsters go into gear with a bump),which indicates the clutch doesn't fully let go till its running, ill let you know tomorrow if mine's the same.

[crosshairs65]

Nice video..very well put together...

[Moonfleet41]

@crosshairs65 Why thanks buddy, thats kind of you to say... hope it helped you.! Del.

[Warpfield]

Does it matter what gear you leave it in before adjusting the clutch?

[Moonfleet41]

@Warpfield You don't adjust the clutch with the transmission in gear, you must adjust the clutch in Neutral..... NEVER IN GEAR..!

[Warpfield]

@Moonfleet41 Yeah, that what I did. However there is something else going on in the clutch pack somewhere. I wound up taking it to the HD Dealer and they rand the clutch adjustment all the way in and out a few times to loosen it up, lubricated and adjusted the cable. However this didn't fix the problem. There is still grabbing when in 1st gear and clutch squeezed and the higher gears are still slipping under load. They are going to keep a the bike a while and research the cause.

[Moonfleet41]

@Warpfield Bad news buddy, sounds puzzling that one!.. at least you had a go at it yourself, and tried the obvious things, and iff the dealer cant fix it without further investiagtion then it proves that you missed nothing and it was not your use and innept fixing,,,, good to prove to them you have a brain and know how to check things, it gets respect and prevents them BS'ing you when it comes to the final diagnosis.. id be interested to know what the find in the end buddy.. good luck with it.

[bugzapper60]

Very imformative thank you

[Moonfleet41]

@bugzapper60 Thank's Bugz', im glad you found it useful mate,,, and hope it saved you handing yer hard'earned wages over to the dealer too..! cheers, Del.

[bikerx1981]

hey there, I have been having problems with my clutch adjustment, i have read my book and watched your video here and did what you show and explain, and it still gives me problems, when i start my bike and pull in on my clutch and put it in gear it acts as though its in gear and wants to take off, while my clutch lever is pulled in, i am baffled by this and it dont make any sence, would you or anybody else be able to have any idea as to what could be the problem, thanx

[Moonfleet41]

@bikerx1981 ill send you a reply in PM, there is more space and i can explain better...... sounds like you may have a buckeld plate maybe..

[Kris10web]

The birds in the background add a simplicity to it all - a nice peaceful feel to servicing a Harley! Good show!

[Moonfleet41]

@Kris10web Hey thanks buddy, you're too kind, i kind of dont notice the birds singing... but when the horses fart in the field out back, we crack up and have to cut and rerecord..lol.... take it easy brother. and dont pay the dealer..

Del.

[seanmccombe]

Hi, Sean here from Canada and I gotta tell you that you are the man. You have just saved me a ton of cash by watching your video. I too have an 883 Sporty and love the bike. Thanks so much for your help and info. Keep up the awesome work.

[Moonfleet41]

@seanmccombe , Hi Sean, you are too kind Sir, i make the videos to help hard working guys keep the bills paid and feed the family... workshops charge rediculous money for hourly rate now, and when you realise what a simple task most of these jobs aye it pains me to hand over so much money when you can to it yourself..... Im glad it helped you buddy, take care, ride safe, and keep it real... Del.

[DarkcustomBear]

man you are a legend! I watch your vids all the time since buying my brand new Iron 883. Now I can feel confident about working on my own bike. Please keep them coming they are very well appreciated, fuck mate how bout a DVD release? I'd buy it for sure.

All the best man!!

Bear

[Moonfleet41]

@DarkcustomBear Why thankyou sir, you are too kind, its just because im tight, (or skint) and cant afford Harley workshop prices and started teaching myself... anytime you have a question, please feel free to ask, knowledge is for sharing, and if i dont know then ill have a mate who will.... ride safe and easy buddy.... Del.

[sabrecatsmbass]

thanks for such a great informative video. keep them coming. used this video to service our sportsters.

[Moonfleet41]

@sabrecatsmbass Hi Sabre, many thanks for your kind comments, im really glad the video saved you some bucks, every little helps aye..lol?. and BTW.... i LOVE those boats..gizza go mister..lol.

[xxpainedxbeautyxx]

Great video. Just replaced my clutch cable after it broke. This video helped a lot.

[Moonfleet41]

@xxpainedxbeautyxx Hi Beth, im glad it was of help to you, and saved you some bucks too. Its good to have contact and support from my buddies in the States. Take care and ride safe hun..

Regards

Del.

[1supermanprime]

just to make sure then, i loosen the cable first then turn that adjustment screw all the way left "counter clockwise" till it gets tight , or snug rather, then turn it a quarter turn clockwise. is that correct? thanks for the reply.

[Moonfleet41]

@1supermanprime YES 100% correct, .. Like i said before and in the video, its natural to presume it winds inward.. but once you see it dismantled you see that the screw is inserted from the inside facing out, when it is mistakenly wound IN.. it has no short term cost, but will slip in hot weather and lead to plate wear... Just to check the cable is slackened enough, poke the head of the cable inside the primary case to make sure it 'jiggles' free of the fork it sits in, hope that help mate..

[1supermanprime]

when you do that clutch adjustment part, what exactly do you mean when it seats? i turned it like 6 or 7 times to the left and now i am unsure where it is supposed to be at..

[Moonfleet41]

@1supermanprime Hi buddy, as long as you turned out "ANTICLOCKWISE" then it usually stops against the seat within about two turns max,.... but if you have had to turn it 6 or 7 revolutions... then it looks like the reason is that somebody who did it last time made the common mistake af turning it IN or CLOCKWISE...

Whatever you have now... just make sure it is one quarter turn IN from fully out... (so turn to the left until it stops... then turn one quarter to the right..ok?)

[TheMorpheus73]

Great video! I will follow this step by step on my 1200XL:-)

[Moonfleet41]

@TheMorpheus73 Thanks Morph', glad its of use to someone. good luck with it, its pretty simple just make sure not to mince them crappy torx bolts, they truly are made from cheese..!

Regards

Del.