Motorcycle Repair: 1980 Sportster Clutch, clutch lever, clutch release


Question
Had to replace shift rod and now i cant get the clutch to disengage.  Help  

Answer
Jack, IF everything is back together correctly, you just haven't adjusted the clutch release properly.  Loosen the cable adjuster locknut (on the front of the primary cover) and screw the adjuster into the primary cover until your clutch lever flops completely loose at the handlebars.  Remove the access plug at the center of the clutch and loosen the locknut.  Turn the center screw inward until it gets hard (makes contact).  Turn it in 2 more turns to make sure clutch is released.  Now adjust your clutch cable so it has no freeplay and tighten the locknut.  Go back to the clutch release screw in the center of the clutch and back it out until it is free.(no pressure on it)  Find the point where it just makes contact turning it in, and back it off a quarter turn from there.  Hold the screw in that position while you tighten the locknut with an 11/16 offset box wrench.  That should do it.  Those year Sportsters (up to early '84)have this tricky setup and if you don't do it exactly in that order your clutch won't work right.