How to adjust the clutch on your Harley

As you know the clutch is a key component to your ride. It can drastically change the overall feel and ride quality of your motorcycle, so ensuring it is adjusted properly is huge. Not only will this effect your ride but as well as the clutch and cable's life. In this article we'll cover how to adjust the clutch and some tips on tailoring it to your riding style.

Motorcycle Clutch

First, let’s recap the purpose of your clutch. In short, it engages and disengages the drive from your engine to the transmission.

For a more technical breakdown, follow along. The Clutch hub is fixed to the transmission shaft. The steel clutch discs are spun by the hub by teeth built into the steel plates. The clutch basket is free floating on a bearing pressed onto the clutch hub and is driven by the engine via the primary chain. The clutch basket spins the friction discs using teeth built into the friction discs. With the clutch lever released, the friction disc are pressed against the steel disc via the clutch spring/s. This will allow the clutch basket and hub to spin as one unit at the same speed, transferring to power from the engine to the transmission. Once the clutch lever is pulled, the clutch spring compresses, releasing the friction discs from the steel discs, allowing the basket to spin freely from the hub. This allows the engine and transmission to spin at different speeds. 

Process for Clutch Adjustment 

Please note this article is a general guideline for clutch adjustment. To ensure proper operation we recommend to reference your service manual. 

1. Remove clutch cable cover. On the clutch cable, there is a cover, or rubber “boot,” that protects it from any dirt or moisture, ensuring a longer lifespan. This is halfway between your handlebars and bottom frame. When you slide this up or down, it will reveal the adjuster hidden from it. If there is any signs of corrosion, be sure to use some lubricant!

2. Add slack to the cable. This will ensure the cable does not interfere with the adjustment done at the clutch hub. Using a 2 wrenches, hold the clutch cable with one and loosen the jam/lock nut with the other. Now collapse the cable as much as possible, creating slack. The clutch lever should have no tension on it after this. Tip, this would be a good time to inspect and lubricate the cable.

3. Remove the derby cover. The derby cover, or clutch cover, is taken off by unscrewing a few bolts. Watch out for any fluid that may leak if your bike is at an angle (preferably upright and on a lift). Be sure to hold onto the derby cover until all screws are out so it doesn’t abruptly fall. 

4. Loosen the clutch hub adjustment jam nut.

Big Twin models: This nut is found under the derby cover and has a threaded bolt going through it. Use a wrench or socket and loosen the nut counter-clockwise. 

Sportsters: The jam nut is held into the clutch by a spring against the derby cover. It may fall out when removing the derby cover. 

5. Adjust clutch using the set screw in the clutch hub

Big Twin models: With the jam nut loosened, use an allen wrench and loosen the set screw counter-clockwise. Next, use the same allen wrench and lightly thread the set screw back in till you feel the first sign of LIGHT resistance. We recommend to use two fingers to spin the wrench.  It may take a time or two to find the sweet spot. Then from there, back off the set screw 1/2 to 1 full turn. We'll go over how the turns out distance effects clutch lever feel in the following paragraph. After set screw adjustment, use an allen wrench to hold the screw from turning while tightening the jam nut with a wrench. We carry a great tool from Motion Pro that makes this easier!

1/2 turn out is good for most riders. This releases the clutch above halfway through the lever's travel. This is a safe setting to ensure easy shifting, finding neutral and help prevent creeping while sitting in gear.

3/4 to 1 turn out release the clutch closer to the grip. This may help riders with smaller hands however it can cause the clutch plates to have not enough separation. This may cause difficulty in shifting, finding neutral, and creeping while sitting in gear. This depends on the condition and style of the clutch plates.

Sportster models: With the locking nut/spring combo remover, turn the adjusting screw clockwise using a flathead screwdriver. Then lightly screw it back in (counter-clockwise) till the you feel the first sign of LIGHT resistance. This may take a time or two to find the sweet spot. Once there, screw out (clockwise) 1/4 turn. Once set, carefully place the nut/spring combo back over the adjusting screw. Note the screw may need to be slightly turned to line up with the slot in the nut. Tip, using some grease on the nut/spring can hold it in place for you while reinstalling the derby cover.

6. Put the derby cover on. Be sure to clean any old gasket material off the primary cover and derby cover. Reinstall the derby cover with a new gasket. 

7. Adjust the clutch cable. Now you are adjusting the slack back out of the cable. To do this, you are doing the opposite of step 2. First pull the clutch lever to the grip. Then adjust the clutch cable nuts away from each other till the lever fully extends. Carefully pull the lever a few times to help settle the cable. Next, pull the clutch level back in, then while releasing it pull the clutch cable away from the lever perch housing. Measure the gap between the cable and housing. A general spec is about a 1/8" gap (about the width of a Nickle). If the gap is too large, continue to separate the clutch cable adjusting nuts. Repeat the previous process till cable slack/gap is correct. Once gap/slack is set, tighten the cable jam nut to the adjusting nut.

8. Reinstall clutch cable cover. Just as you started this process, you end it. Slide your cable cover back over the adjuster so it can keep out dirt and water. If you want to make this even easier, a spray of silicone will let the cover slide more freely to be put back in place and help prevent corrosion.

Final Thoughts

And you’re done! Adjusting the motorcycle clutch on your Harley is a relatively stress-free job, but one that needs to be done every so often to ensure a smooth ride. If you are hesitant at any part during the process or would like it adjusted by a professional, contact the experts at Ramjet Racing for some prompt advice and help.