So I just did my 5000 mile service on my bike. Everything went easy like it should until the clutch adjustment. I did it like the manual said ohhh about 6 times. It would never adjust correctly. It wouldn't allow the clutch to fully disengage and the bike wouldn't move. I got on here and followed some instructions that I found on another post that got her moving again. When I did it I found that my adjusted is out 3 full turns in order to operate right. Why would this be so far out of spec compared to the manuals 1/2 to 1 turn guidance? It seems to shift and ride fine. Finding neutral isn't a problem, the 2 turn difference just has me curious.

 

You had the slack out of the cable and then tightened the clutch adjustment screw until you felt slight pressure, then backed it off 3 full turns from there? As in 360 degrees times 3? Wow, I have no idea!

 

Something ain't right. Did you bottom out the adjuster a few times until you felt resistance prior to going 1/2-1 turn back? Did you reseat the ball/ramp assembly by squeezing the lever prior to finishing the adjustment? You collapsed the cable adjuster prior to the basket, correct?

 

Three turns? That doesn't sound right. I waited until the engine was completely cold, followed the service manual to the letter, and nailed it the first time. Clutch felt brand new. You can definitely feel the resistance when you get there. A half turn back and it should be just about perfect.

 

yeah, I did it exactly how the manual said. When I did it at a half turn, I couldn't even pull the clutch lever back half way. It had a lot of resistance. Then I went 1 full turn, and it improved a bit. I put the cover back on and reset the cable, but when I started it, it wouldn't move. So I pulled it back off, re did the adjustment with the same outcome. I know that when I tightened the adjuster the first time, it went way more than 1/2 to 1 turn to bottom it out. I should have counted, but didn't. I would say it was close to 2-3 turns to get it to bottom out. So then I went off of some instructions that I found on here, that had me take the cable adjuster all the way out, then pull the lever in, screw the clutch adjuster in untill it pushes the lever away from the bar. Then I backed it back off untill the lever came back into contact with the bar, and went another half turn. When I put it back together the clutch would work but slipped. So I did another half turn and it feels good. Grabs about an inch away from the bars and feels like it used to.

 

That shouldn't be done that way, creates too much play. HERE's a post from hog-doc that explains why you shouldn't do it that way.

 

[QUOTE=ddan1130;6893597] So then I went off of some instructions that I found on here, that had me take the cable adjuster all the way out.................. QUOTE]

And there is your problem....you collapse the adjuster....not take it all the way out.

 

You should have about a nickel of play when done

 

got it after watching a video from another post on here. I was bottoming out the set screw ALL the way, obviously fully engaging the clutch and not giving it enough room to fully seperate. So after pulling it apart yet one more time and really feeling for where the resistance started, it was good to go in all of 10 minutes. Thanks for all the help, glad I got it figured out (from a lot of good advice throughout this site).