Motorcycle Repair: 2002 Harley Davidson clutch engagement, clutch lever, clutch cable


Question
QUESTION: I've recently acquired a 2002 Patriot motorcycle with Harley new EVO motor and trans. The clutch cable outer surface had some damage on it so I removed the cable, fixed the damage (external cable cosmetics only - nothing near the inner cable), reinstalled the cable, filled with oil and adjusted the cable so there's a little play at the lever.

With the bike in gear, motor not running, when I depress the clutch lever the clutch doesn't disengage the tranny (bike will not roll). Shift into neutral and the bike rolls just fine.

The clutch "feels" like it's working correctly and when I took the clutch cover plate off I can see the plates moving when I depress the handle.

I don't have much experience working on motorcycles but have been repairing/rebuilding autos for 30 plus years.

Thank you for any and all assistance you can give me.

ANSWER: When you adjusted the cable, did you adjust it at the clutch as well as at the cable adjuster?
Mike

---------- FOLLOW-UP ----------

QUESTION: No, since I removed and replaced the same cable I didn't think the clutch needed adjustment also.

How do I adjust the clutch?

Thank you

Answer
Loosen the adjuster on the cable so you have some slack in it. Go to the adjuster on the clutch and loosen the locknut. Turn the adjuster screw outward a few turns and then inward, just until it seats, then back out about 1/8 of a turn. Tighten the locknut. Go back to the cable and adjust it so you have about 1/8 inch play in the clutch lever and your set
Happy holidays
Mike