How to adjust your clutch (05 and newer)

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tacoloco

tacoloco

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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

Loosen lock nut and turn adjuster clockwise to loosen cable and give full slack to your clutch lever. It should look like this.

Now remove the clutch adjusting cover to access the adjusting hardware.

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.

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.:)
 
BBChopper

BBChopper

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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:
 
Alicat

Alicat

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

tacoloco

Member
lee said:
tacoloco - did you have to take your exhaust off to do the adjustment?
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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.
 
TCALZ06

TCALZ06

Well-Known Member
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.
 
Raywood

Raywood

The Pirate
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TCALZ06 said:
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.
Click to expand...
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:
 
G

gooddoggie

Member
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.
 
ROCKETDOG

ROCKETDOG

Active Member
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.
 
outlawcrewcab

outlawcrewcab

Member
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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