I’m having clutch problems with my 2003 1200xl.

Started about a month ago. The clutch cable developed significant play. I made adjustments by lengthening the clutch cable. Worked for about a week and some more play developed. Adjusted the cable again but this time I could hardly shift. I removed the clutch cover and adjusted the clutch with the clutch adjusting screw. That worked for about 2 weeks and play in the cable started to come back… additionally the clutch sometimes makes a high pitched squeal… any thoughts on what is going on??

 

How many miles you have on it? Is it just the cable you're having problems with, or is the clutch itself slipping and/or dragging? My guess, brass rivets in the spring plate. I had the same issue. Common problem in Sportsters. If you've still got the warranty on it, that'll cover replacing the clutch. It could be something simpler, of course. The throwout bearing could have gone, for example. The only way to be sure is to open up the primary and take a look.

 

Have you checked the cable for fraying or twisting?

Sounds like you are close to a snap.

 

Original equipment? Replace cable, pull clutch and check all components

 

I have about 23,000 miles on it.... thanks for the advise.

 

Sounds like it is the release bearing going out.

 

Happened to me. Cable outer cover slipped which made inner cable appear longer. Could adj it out at first but just got worse. Replacement fixed it.

 

OK for those of you with a similar problem it turned out that the bering on the adjustment screw was completely shot... new clip new bearing and back on the road...