Motorcycle Repair: clutch adjustments, clutch springs, clutch lever


Question
I can't seem to get my clutch adjusted right on my 57' Sportser.I either won't fully disengaged and won't go into gear or it slips like crazy.

Answer
It's a little tricky and has to be done in the correct order.  I have to assume you haven't overtightened the 6 adjusting nuts on your clutch springs first.  The inner surface of the spring adjusting plate (the wavy plate) has to be at least 3/16" from the outer surface of the flange on the spring cups, and even all the way around, or your clutch won't release.  Anyway, on the right side, loosen the center adjusting screw locknut and back off the adjusting screw until the releasing worm lever behind it returns against its stop (there is a little return spring to pull it against the stop).  Now adjust the clutch cable length by backing out the handlebar cable adjuster just until the releasing lever (behind the kicker cover) comes off it's stop.  This will hold the clutch lever in it's fully extended position.  Now turn the adjusting screw in until there is about an eighth of an inch of free play at the hand lever.  Tighten the locknut without moving the adjusting screw.  The trick with these is you have to first do the cable adjustment correctly or you will never get the release adjustment right.  Make sure the cable is lubed and free in its housing, and the hand lever is fully seated against the handlebar clamp before you do the cable adjustment.