Clutch Notes

Here's some internet info I gathered to help me understand clutch adjustment.

Clutch Adjustment:

a. Slide rubber boot off cable adjuster. Holding cable adjuster with ½ wrench,
loosen jam nut using a 9/16 wrench (nut size may vary depending on cable
manufacturer) Turn jam nut to top of cable, which moves it away from cable
adjuster. Back off cable adjuster with wrench toward jam nut, which creates free
play at the hand lever. Nut size may vary depending on cable brand

b. Remove the five screws on the derby cover and remove derby cover.

c. Using an 11/16 wrench, loosen the clutch adjuster nut. May have to insert a
7/32 allen wrench in adjuster screw to keep clutch from turning while loosening
clutch adjuster nut.

d. Using your fingers, turn the clutch adjuster in until it seats against the
clutch release. Seated means that it is lightly touching the release.

e. Back the adjuster out 1/2 to 1 full turn from seated. Repeat this several times
to get all the play out.

f. Lock the adjuster nut down while holding the adjuster from turning using the
7/32 allen wrench.

g. Squeeze clutch lever to maximum limit three times to set ball and ramp release
mechanism.

h. Turn cable adjuster away from jam nut until slack is eliminated at hand lever.
Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn
cable adjuster as necessary to obtain 1/16“ 1/8 free play between end of cable
ferrule and clutch lever bracket.

i. Hold adjuster with ½ wrench. Using 9/16 wrench, tighten jam nut against cable
adjuster. Cover cable adjuster mechanism with rubber boot.
Nut size may vary with brand of cable

j. Install the derby cover after topping off primary oil if needed.

Miscellaneous notes:

At the clutch pack: Adjusting the clutch adjuster screw adjusts the point at which
the cable begins to pull the clutch out of engagement. If you turn the clutch
adjuster screw clockwise, you adjust toward slippage, if you turn it
counterclockwise, you increase the slack before disengagement (drag). If the
adjustment screw is turned too far clockwise, the clutch will be disengaged or slip
no matter what position the cable is in. If the adjustment screw is too far
counterclockwise, the clutch will drag because you cannot, regardless of how much
slack you remove at the lever, disengage it enough to remove the contact

1/8 to 1/4 turn of the adjusting screw reduces your friction zone, clutch lever
almost all the way out from handgrip before clutch engages. 1/2 turn is the stock
adjustment, which is just fine for most riders. Motor officer will have their
clutch adjustment screw turned 3/4 to 1 full turn from being lightly seated to have
their friction zone begin close to the handgrip during their rodeo exhibitions.
Unless you're a trick rider doing lock-to-lock low speed turns etc, recommend
adjusting no more than 3/4 turns.

If you want the clutch to release closer to the grip, back off adjuster, after
slight tension is felt 3/4 to 1 turn. If you want it to release farther from the
grip, back off the adjuster 1/4 - 1/2 turn. Backing adjuster screw ½ off ensures
clutch will disengage.

The adjustment of the nut in the clutch pack alters where the friction zone ends up
on the lever on the bars. If you have the friction zone real close to the handgrip,
it will not give you good separation of the discs and it will be hard/noisy
shifting because of this and be harder finding neutral. Further away from the bars
(with 1/2 turn out) will give you better separation, which will be easier shifting
and finding neutral.

To take up all free play in push rods, turn screw inward (clockwise) until lightly
seated. The service manual recommends ½ to 1 turn after turning the adjuster screw
counter clock wise to lightly seat the screw.

If you follow the procedures in the service manual, with 1/2 turn the clutch will
engage further from handgrip as you release the lever. If you adjust the screw 1
turn, the clutch will engage closer to the handgrip as you release the lever.

In effect when turning the clutch adjustment screw; you are adjusting the push tube
and setting where the ball and ramps start to disengage the clutch. The release
bearing is also known as the throw out bearing (on right side of bike). When you
pull in your clutch lever you are compressing the clutch springs allowing the
clutch plates to disengage. Imagine a rod (pushrod) pushing on something that is
spinning - if there wasn't a bearing (throw out) the rod wouldn't last too long.

At the lever: Use the cable adjuster to increase / decrease slack at the hand lever
to about 1/8”. Too much slack and clutch may drag / too tight and clutch may
slip. If lever play is more than 1/8” at the handlebar, clutch may not fully
disengage.

Most Harley Davidson lever positions are set at about 1/8" of play. However, the
best positioning of the lever is where it works best for you - as long as it still
"works" or gives you the best control over the clutch's operation. There are
boundaries you want to stay within. Do not adjust the lever too tight where it will
slip, or too loose where it will not disengage all the way. Keep the lever clean
and lubricated, including the lever pivot pin

#1 most common problem with finding neutral is associated with clutch drag. If the
lever play is more than 1/8" at the handlebar you may not be fully disengaging.

The closer you feel the friction zone near the handgrip, the less separation you
get in the clutch plates. You may then experience hard shifting, difficulty finding
neutral and faster clutch plate wear.

As the clutch plates wear, the stack gets shorter and push rod endplay is reduced.

- Determine the O.A.T. (Overall Thickness). This is the combined thickness of all
steels and frictions. Basically, this must not vary to any great extent from stock.
You can use more or fewer components, but stack height must remain the same. Too
thin a stack may result in slippage, while too thick a stack may cause drag.

- Stock clutch height 1998-2006 is 1.850”

Slippage:
1. Clutch controls improperly adjusted.
2. Insufficient clutch spring tension.
3. Worn friction plates.
4. Warped frictions or steels.
5. Improper cable adjustment.

Drags or Does Not Release:

1. Clutch controls improperly adjusted.
2. Clutch spring tension too tight, coil binds.
3. Friction plates gumming up.
4. Clutch shell keys or hub studs badly worn.
5. Clutch plates warped (metal or frictions).
6. Clutch cable collapsing, improperly adjusted.
7. Improper adjustment on primary chain/belt.
8. Too heavy an oil has been used in the clutch. A thick viscosity oil can casue
the plates to stick, especially when cold.

Chatters:
1. Clutch hub liner friction plate rivets loose or broken.
2. Clutch spring disc too flat (diaphragm).

Q: What is the purpose of the oil in a 'WET' clutch?

A: The primary purpose of the oil in a wet clutch is to act as a coolant. The oil
in the primary chain case flows around the clutch plates and friction plates,
cooling them. This results in smoother clutch action and prolongs clutch life.

Q: What about using Synthetic Oils in my clutch?

A: Synthetic oils, by their very nature of better heat resistance and improved
lubricating properties, would seem to have an advantage. This is an advantage when
it comes to lubricating an engine or transmission, but turns into a disadvantage
when used in a clutch. This increase in lubricating properties (they are slippery)
can cause an old, worn out clutch to fail. The purpose of the oil in a wet clutch
is to cool, not to lubricate. The more 'slippery' an oil is, the more likely a
clutch is to slip, resulting in increased heat and creating excessive wear. While
most high performance clutches are designed to work with synthetic oils, it is not
recommended that they be used by most clutch manufacturers.

Q: What causes my clutch to stick or drag?

A: There is no single cause of a sticking clutch. Some more common reasons for a
sticking clutch are:

- Clutch controls are improperly adjusted. Clutch cable is collapsing.

- Clutch spring tension is to tight, spring binding.

- Too heavy of an oil has been used in the clutch. A thick viscosity oil can cause
the plates to stick, especially when cold. Use a light viscosity motorcycle
specific oil (10W30 / 10W40)

- Clutch oil is 'worn out' or burnt. The oil has been in the clutch to long, clutch
plate wear is excessive causing slippage, or a driving style that slips the clutch.
Changing the oil in a clutch often improves the situation.

- Clutch plates are warped. Friction plates or metal plates may be warped.

- Improper adjustment on primary drive chain/belt

Q: What causes my clutch to slip?

A: Some of the more common reasons for clutch slippage are:

- Improper cable adjustment.

- Improper clutch adjusting screw tension

- Insufficient clutch spring tension. This can be due to excessive wear or in

highly modified engine, too much power.

- Worn or warped friction plates or steel plates.