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  1. #1

    Join Date
    Nov 2013
    Posts
    11

    Default Clutch cable adjustment

    Hey I'm trying to adjust my clutch cable but am running into an issue. The manual and all the videos I see have the part looking like this
    Click image for larger version. 

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    but mine is like this
    Click image for larger version. 

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    So when I'm adjusting it to the manual it keeps hitting my case. Is there anything different I need to do to adjust this?
    Last edited by kconn04; 09-22-2022 at 3:07 PM.

  2. #2

    Join Date
    May 2015
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    705

    Default

    Year, model bike?

  3. #3

    Join Date
    Nov 2013
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    11

    Default

    1994 sportster 1200

  4. #4
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    Default

    When you are doing the center screw adjustment, the lever on the mechanism will be swung to your right. After you do the screw adjustment and then the cable adjustment, the lever will be swung more toward the bottom and should clear the case in operation.

    You want 1/2 - 3/4 turn of FREE TRAVEL when you do your screw adjustment. Do the cable adjustment last, of course, and you have enough cable adjustment available to make the take-up point at the hand lever anywhere to your liking.

    Don't know if this addresses your question. These clutches & the release mechanism are pretty foolproof.

    Jim

  5. #5

    Join Date
    Nov 2013
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    11

    Default

    Here's some better photos.

    See how mine is sticking out on the outside? When I pull the clutch in it hits the edge of the case so I can't fully engage it.
    Click image for larger version. 

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    Where as all the other ones I see in videos and in the manual it's flat on the outside.
    Click image for larger version. 

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  6. #6
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    Your cable link is on the wrong side of the lever.

    Edit: I think your release assembly is not correctly made. You may have to get another one.

    Jim
    Last edited by JBinNC; 09-23-2022 at 11:09 AM.

  7. #7

    Join Date
    Nov 2013
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    11

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    If you look at my first photos you notice it has to attach this way. Hence my confession

  8. #8
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    That is odd! Might be a Chinesium aftermarket part.

    http://sportsterpedia.com/doku.php/t...vo:priclutch01 is what things are supposed to look like.

    They're cheap new but I've never seen one worn enough to matter so I'd throw in a used (Harley etc, not Chinesium) one if handy. Used is about 20 bucks shipped on Ebay and Ebay shippers tend to be quick to preserve feedback.

    Random example, not mine:

    https://www.ebay.com/itm/26406691971...temCondition=4

  9. #9

    Join Date
    Nov 2013
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    11

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    Thanks farmall. I did some more digging and apparently they used 25409-86A for a bit and then I guess they realized it was a stupid idea and changed it next year to 25409-94B. So I got the original. And yeah they're cheap enough that I'll just get a new one.

  10. #10
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    The old part number is of course for four speeds but lingered. Five speed outer primary covers came in two flavors, one requiring removal to replace clutch cables and a later version that doesn't. (The late covers retrofit so I scored those parts for one of my Sporties.)

    https://www.facebook.com/groups/1465...ghts&ref=notif

    is worth a dummy account as they have links to a very large selection of FSM and parts catalogs for free download with no nonsense. Best to pig out for a healthy reference library. Sportsterpedia is excellent too.

    http://sportsterpedia.com/doku.php/t...vo:priclutch02

    Fortunately your 1994 has the "good" outer primary cover arrangement.

  11. #11
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    https://www.ebay.com/itm/12534409634...Bk9SR464tcT0YA

    Could be a thought .. ??

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