2003 Harley Davidson XL 1200 C Sportster Custom Logo
Posted on Jul 12, 2014
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After a gear oil change how do i adjust the clutch

1 Answer

Harry Goodwin

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  • Expert 353 Answers
  • Posted on Jul 31, 2014
Harry Goodwin
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Joined: May 07, 2009
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Because the clutch cable adjuster clearance increases with engine temperature, adjust
the clutch when the engine is cold. If the clutch is adjusted when the engine is hot, insufficient pushrod clearance can cause the clutch to slip.
1. Remove the clutch mechanism inspection cover and
quad ring
2. Remove the clamp and slide the rubber boot off the clutch in-line cable adjuster.
3. Loosen the adjuster locknut and turn the adjuster to provide maximum cable slack.
4. Make sure the clutch cable seats squarely in its perch at the handlebar.
5. At the clutch mechanism, loosen the clutch adjusting screw locknut and turn the adjusting screw clockwise until it is lightly seated.
6. Squeeze the clutch lever three times to verify the clutch balls are seated in the ramp release mechanism located behind the transmission side cover.
7. Back out the adjusting screw counterclockwise 1/2 to 1 turn. Then hold the adjusting screw and tighten the locknut to 72-120 in.-lb.(8-14 N•m).
8. Once again, squeeze the clutch lever to its maximum limit three times to set the clutch ball and ramp release mechanism.
9. Check the free play as follows:
a. At the in-line cable adjuster, turn the adjuster away from the locknut until slack is eliminated at the clutch hand lever.
b. Pull the clutch cable sheath away from the clutch lever, then turn the clutch cable adjuster to obtain the clearance gap
c. When the adjustment is correct, tighten the clutch in-line cable locknut and slide the rubber boot over the cable adjuster.
10. Install the clutch inspection cover quad ring onto the primary chain case cover.
11. Install the clutch inspection cover and tighten the screws to 84-108 in.-lb. (9.5-12 N•m).

1 Related Answer

Anonymous

  • 218 Answers
  • Posted on Jun 05, 2010

SOURCE: Harsh gear changes up and down

sound's like it need's a clutch, to test this put the bike in first gear and with both fron't and rear brake's applyed try to move the bike, it should stall out or it will slip telling u it's time for a new one

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Related Questions:

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Why dose my transmission slip in higr gear on my 2000 boss hoss

generally high gear is when your clutch is most stressed so you're looking at replacing them. It's not too difficult just time consuming.
Be sure your clutch cable isn't binding and adjusted right, you may have some adjustment left to temporarily help.
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1.2 manual reverse gear problum

Manual transmission does not change gears with transmission oil. If yours is the AMT type, get it scanned for error codes.If the problem is in shifting into R, get your clutch cable adjusted. Your clutch plate may have also worn out. If shifting is OK but the car just does not move, the gear linkage/cable may need adjustment. If all else is OK, the reverse gear in the transmission may have been damaged.
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2nd gear started not ingaging at times downshfts no prob checked main clutch adj 1/2 turn off perfect found gear oil like 90 weight in primary had service down at 10,000 at hd someone put gear oil indid it...

The thick oil has probably not harmed anything. It will make it harder to shift because it gets into the clutch pack and acts like a hydraulic fluid in a torque converter. I'm betting that now that you've changed the oil to Syn3 that it'll shift better. Just make sure you don't overfill the primary. With the bike standing straight up, remove the derby cover. The oil level should be no higher than the lowest point on the clutch spring. If you look at the clutch assembly, you'll see that there is an aluminum ring around the outside of the clutch with a darker colored disc in the center. The dark disc is the clutch spring. Fill the primary just up to the lowest point on the dark disc just over the bright ring.

If this does not improve the shifting into second gear, have the dealership adjust the shifter pawl adjustment. It takes some special tools to get to the adjustment.

Good Luck
Steve
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I have a 2005 Suzuki C90 which stalls when put in gear.

Hello,

It sounds like a clutch issue. If the clutch is adjusted properly, I would let it warm up longer before trying to engage the clutch and put it in gear. Also, have you changed the oil lately... and if so, did you use the manufacture's recommended oil? Some bikes have an inherent problem just as you have described and an oil change or slight clutch adjustment usually lessens/fixes the problem.

Hope this helps. If you find this information useful, please vote on this post. Thank You.

Regards,

Oz
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Suzuki rm125 1986 model, clutch will not engage

hi buddy use 750mls off light gear oil buy silkolene light gear oil buddy also try adjusting the clutch cable and it shal run ok get back to me if no change
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Hi, i have a 82 kawa kz750 it started off as

It sounds like your clutch pack is worn out. When you rev it up you heat up the friction plates between the clutch plates and it will grab because it gets hot.
One thing you can check before is clutch cable adjustment. hope this helps KC
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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.
3helpful
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I have a suzuki rm 125 1994 model when i pull the clutch lever in to put it in gear the clutch doesnt work t jst crunches into gear

Adjust the clutch cable to allow about 1/4" free play at the end of the clutch handle. Don't put the bike in gear until the rpms are near idle speed. The clutch is working fine if the bike does not lurch forward when going into gear at idle speed. Dirty, gritty oil in the gearbox can make the clutch grab. Consider changing oil if grabbing is the problem. The "crunch" you hear is the slider gear engaging into the driven gear. The higher the engine speed when being put into gear the louder the crunch. The slider gear engaging "dogs" can break. Crunching into gear is hard on the gears.

Post a comment to let me know how you come out on this.
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I recently had a new clutch fiited on My peugeot 406 GLX 1999 model, and lately the gears have been stiff.

this could be 1 of 4 things

you have become use to change characteristics of the old well worn/broken down oil - but even so new oil should not be excessivey stiffer

incorrectly adjusted clutch - although 406s had a self adjuster cable

incorrectly installed clutch

or most probably

wrong gear box oil - i have experience this, garages will use one grade/type of gear oil - check what spec your car is meant to have and change it - it made a huge difference on my peugeot

the oil filler and drain are accessible by removing the road wheel on the gearbox side of the car
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Changing gears very stiff

try 1 0f these solutions giving the cars age and not much discription.
1 check the level of your gear box oil

2 change the gear box oil or if automatic change the fluid for the transmision.( since you say changeing gears i take it that it's manual gear box.

3 if manual the gears need over hauled giving the age of your car.

4 your clutch cable needs adjusted due ware on the clutch or if hydraulic the clutch system needs bleed with new fluid.
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