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How to adjust your clutch (05 and newer)

Discussion in 'How-To' started by tacoloco, Jan 2, 2008.

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  1. tacoloco

    tacoloco Member

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    My shifting was hard and finding neutral was difficult. After adjusting my clutch, my shifting is now smooth and finding neutral is a breeze. This is how I did it. After leveling the bike, slide the clutch cable boot to access the cable adjuster
    [​IMG]
    Loosen lock nut and turn adjuster clockwise to loosen cable and give full slack to your clutch lever. It should look like this.
    [​IMG]
    Now remove the clutch adjusting cover to access the adjusting hardware.
    [​IMG]
    Loosen jam nut with 11/16 wrench and turn pushrod clockwise with a 7/32 Allen wrench until stops (only with light force) now turn pushrod counterclockwise ¼ of a turn and tighten jam nut.Install cover.
    [​IMG]
    Finally adjust your cable to give your clutch lever 1/16 of free play. Tighten the jam nut and slide the boot back in place.
    Enjoy your smooth clutch. If this adjustment doesn’t do the trick for you, consult your near BD dealer.:)
     
  2. Gas Man

    Gas Man Cool isn't cheap
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    Good work
     
  3. Chopper Dave

    Chopper Dave SIICK!!!

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    good post!:up:
     
  4. f-okie

    f-okie AllGaveSome-SomeGaveAll

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    Very straight forward:2thumbs:
     
  5. lee

    lee Well-Known Member

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    good shit that - I need to have a look at mine so very useful
     
  6. BBChopper

    BBChopper Supports 2 Disabled Vets
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    Great post tac!!!!:2thumbs:
    Hey Lee place a pin on the map so we can see just where ya are over there!:eek:
     
  7. seatmaker

    seatmaker Well-Known Member

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    Thanks, saved to my favorites !!! That's worth a rep:up:
     
    #7 seatmaker, Jan 5, 2008
    Last edited: Jan 5, 2008
  8. Alicat

    Alicat Hanging out

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    Great post! I've been having all kind of problems with my clutch cable since they replaced it....
     
  9. lee

    lee Well-Known Member

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    how do I do that?
     
  10. lee

    lee Well-Known Member

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    tacoloco - did you have to take your exhaust off to do the adjustment?
     
  11. lee

    lee Well-Known Member

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    ok - I've done it
     
  12. seatmaker

    seatmaker Well-Known Member

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    Did it work? :zdrool:
     
  13. tacoloco

    tacoloco Member

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    Lee, I took my exhaust off to see if I could do any mods to it. You don't have to remove your exhaust to do the clutch adjustment. If your allen wrench does not fit, cut it in half to work around the exhaust.
     
  14. slowrower

    slowrower 2007 Mastiff

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    Thanks ... Good info to have when it comes time to make the adjustments. :2thumbs: :2thumbs:
     
  15. TCALZ06

    TCALZ06 Well-Known Member

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    Great write up I just used it after dealer F'd up my clutch adj on my 5k service


    you might want to mention that the clutch adjusting cover spins off and I had to use a oil filter wrench with a adj rubber band to get it off.
     
  16. Raywood

    Raywood The Pirate
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    Yeah, that SOB gets tight!!! I won't mention that I couldn't get mine loose but the mechanic at the dealer turned it right off........... Won't tell you SHE was a small little girl!!! :eek:
     
  17. gooddoggie

    gooddoggie Member

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    Also another method to remove the clutch adjusting rod cover is to pick up one of those rubber tipped door stops at the hardware and saw or grind off the screw end flush that screws into the base board, then just place the rubber stopper end in one of the recess areas of the cover and tap lightly with a small hammer in a counter clockwise direction and it should come off easily, the rubber protects the chrome and won't do any damage. Don't forget antisieze when you reinstall it.
     
  18. ROCKETDOG

    ROCKETDOG Active Member

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    Interesting thread...seeing that I just looked at it today about 30 minutes after my clutch cable broke! Clutch pull was gettin stiff then snapped and my lever was sittin on my grip. It's an '06 Chopper still under warranty - Any How-to threads with pics on handling this? Thx.
     
  19. outlawcrewcab

    outlawcrewcab Member

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    will this work on my 02 with a 5 speed? guess i need to go look
     
  20. outlawcrewcab

    outlawcrewcab Member

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    yep my 5 speed set up is not the same anyone know how to do it? i have the same problem with the bike hard to put in neutrul and its always feels like clutch is draging at redlight always moving forward
     
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