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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #11  
Old 13th March 2007
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Great write up Chris, this is gonna be a very useful sticky!
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  #12  
Old 25th April 2007
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DO NOT FILL TO JUST UNDER INSPECTION WINDOW!!!!!!!

The inspection window is the small removable plate where you check your primary chain tension.

You fill it so that your fluid is just contacting the bottom of the clutch basket with the bike upright. You do this with the DERBY COVER removed.

Other than that faux pas, a very good how to.
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  #13  
Old 27th April 2007
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Thanks supercharger, I said the clutch inspection cover, not the inspection window for the primary chain.

The manual calls the "derby cover" a clutch inspection cover, "derby cover" is the slang for this part.

Hopefully if people follow the post correctly the primary chain inspection cover will still be installed and the clutch inspection cover will be removed and they won't get confused between the two.

Chris
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  #14  
Old 15th May 2007
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When you find that turning the adjuster screw until you feel resistance doesnt work, try rereading the manual or this post, and turning the screw ANTIclockwise.

Every other clutch I ever adjusted the screw went clockwise, so I didnt think twice about which way to turn it, I am doing my own service for the first time, after finding out the stealer wanted nearly ú300 ($600) !
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  #15  
Old 20th May 2007
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Default '97 clutch adjustment

Great Write up. I have a '97 883, I replaced the clutch cable and did all the adjustments per the manual, but the first time every morning I put it in 1st gear, the gears don't mesh, after this first time I can go up and down the gears with no problem. It didn't do this before I replaced the cable. I have played with the adjustments and made sure that the bottom adjustment is out 1/4 turn, the fluid is new and at the correct level, even with the bottom of the Derby cover lip. The top is approximately 3/16" gap. Any ideas? Could the cable be too long?

Thanks
Rich (rsrhawk)
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  #16  
Old 20th May 2007
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If the cable is too long you will have excessive play at the lever I would think, but I could be wrong. Do you have the specified gap at the lever ?? Sounds like if it wont engage the gear when you let out the lever you've adjusted the adjusting screw too far and it is putting pressure on the diaphragm spring and not letting the clutch release.

Chris
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  #17  
Old 20th May 2007
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Quote:
Originally Posted by cjburr View Post
If the cable is too long you will have excessive play at the lever I would think, but I could be wrong. Do you have the specified gap at the lever ?? Sounds like if it wont engage the gear when you let out the lever you've adjusted the adjusting screw too far and it is putting pressure on the diaphragm spring and not letting the clutch release.

Chris
Hi Chris,

What is happening is when I pull in the lever and put the shifter in 1st gear, the gears won't mesh unless I force it. Once it is in gear and I let out on the lever, everything is fine and I don't notice any slippage when I go thru the gears. The cable is a Barnett not the stock Harley and looks longer than the one I took off. The dealer said that I would work fine, but I haven't been able to adjust out this first gear gnashing issue.

I appreciate your help on this.

Rich
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  #18  
Old 20th May 2007
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If the gap at the lever is right then you need to turn the adjusting screw a little more counterclockwise. When you adjust the screw you are supposed to go till you feel resistance then turn it back a 1/4 turn, the problem is that the resistance I feel isn't what you feel, it's something you have to play with till you get it.

Turning that adjustment screw is putting pressure on the diaphragm spring, think of it that way and put a little preload on the spring, then back off 1/4 turn.
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  #19  
Old 22nd May 2007
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Chris,
I went thru the adjustment again and seem to have it in order. Has a little clunk at fast idle, but quiet and easy at idle. Thanks for your advise.

Rich
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  #20  
Old 24th June 2007
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Very impressive and helpful right up, That is great with the pics, this helps me a whole bunch.
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