1990 Sportster clutch adjustment

Answer 1

Adjusting the throw-out clutch adjustment is a snap with a small screwdriver. Gene adjusted the clutch cable tight to afford a user friendly clutch. We used the coin gauge for demonstration, then we decided to remove the derby cover (27 mm Torx screws) to adjust the clutch pushrod. We were beginning to lose Layla. She sat quietly jotting notes, but I could tell her emerald-eyed enthusiasm level waned. "You should adjust the clutch cold and the primary chain hot," Gene pointed out and Layla scribbled, "since the clutch hub grows and tightens the chain with the heat." We jumped to the primary chain inspection cover and checked the chain. Gene point out that the chain adjuster hangs in the open below the primary for easy access. "It takes a 7/8-inch open-end wrench," he said, "a 1/4 Allen and should be adjusted hot." The new Sportster manual called for 3/8 to 1/2 -inch cold and 1/4 to 3/8 inch slack while hot. The throw-out bearing held a spring and lock nut which popped into Gene's hand. It was a breeze to adjust with a small screwdriver after the cable was set free. He bottomed-out the clutch adjusting screw slightly and backed it off a quarter to a half turn (the locking nut position may force some final adjustment). Then he replaced the hex lockplate and spring, then the quad rubber ring and the derby cover. He tightened the Torx fasteners in a crossing pattern to 108-inch pounds. The cover only fit in one direction, but the toughest assignment was that damn quad gasket that constantly jumped out of its groove, until we tilted the bike slightly toward the right. "If the factory can install 'em dry," Gene spat, "why can't I?" With the cable loose we lubricated it with a fine oil. We tightened the cable using the rubber-boot covered adjuster with the coin clearance measurement in mind. "Any coin will do," Gene pointed out. I've adjusted cables for 30 years, yet Gene showed me a new trick. I looked at Layla and was certain she was slipping away. It was an acid relationship test. Occasionally when she thought we neared completion she'd reach for her deerskin gloves, only to substitute them for the notepad again. Gene didn't simply adjust the slack using the position of the lever. He pulled on the clutch cable housing as it entered the lever bracket then tightened the cable adjuster until it showed 1/16 of-an-inch space between the cable ferrule and bracket. We were finished. He coated the cadmium plated adjuster and cable end with grease to prevent damage to the rubber boot and rust from reaching the adjuster.