I just bought this bike. I am getting clutch slippage up above 50 mph or so in 4th and 5th gear with moderate-heavy throttle from about 3500 rpms up. 1-2-3 I can run all the way to the limiter with no slippage.

I did adjust the clutch per specs. Fully releived clutch cable then backed off allen bolt fully, turned in until resistance, back off 1/2 turn....same. Repeated and backed off 3/4 turn....same. Finally repeated and backed of a full turn.....same results. I left around 1/8" free play in the clutch cable.

BUT, when I first pulled the cover and broke the lock nut loose, the gasket directly infront of the allen bolt was worn to the point the metal was exposed. Clearly the bolt was rubbing. Furthermore, the bolt was backed out way too far as I was able to make at least 3 full clockwise turns before resistance was felt, without backing it off..

So could this have worn the clutch beyond the adjustment at only 10k miles on the bike?? I am sure the clutch is now adjusted properly, but still this slippage up high as mentioned (not as readily as before adjustment, but still quite apparent). And when I removed the cover, smells a bit burnt.

The guy I bought it from is willing to refund enough to pay for the parts, so I just have to do the install. Just want to make sure I am not missing anything before picking up a new clutch and manual on my way home tonight and this is infact a worn clutch.

I did get what I think is a good deal on the bike for $10,000 with 10k miles, so not a huge deal to me here. Just want to make sure it is fixed correctly. First Harley for me, so never worked on one. Have owned 3 'other' bikes in the past.

Update: I just bought the screaming eagle kit to rebuild the clutch, so we shall now see I suppose.

 

I found some of the friction plates were quite worn and the oil was dark and smelled burnt. A couple of the post's threads on the clutch housing/basket were stripped so I had to helical insert them. Button it up after work tomorrow and check it out. But all signs point to the bad adjustment ruined the clutch.

 

Worked out fine. Works great. Easy job to do.