Fix It

Clutch adjustment procedures and hardware on all Harley-Davidson Big Twins and Sportsters manufactured since 1990 are identical. Once you learn to adjust the clutch on your bike you can adjust the clutch on any recent Harley. And, with some sight in at least one eye and the slightest practical intelligence you will quickly see how to adjust the clutch on any Harley made since the Second World War. There are only two clutch adjustment specifications for your Custom 1200 Sportster. The first is to adjust the cable lever to 1/8 inch free play. The second is to back out the clutch adjusting screw one half to one full turn. This is how you get there.

Clutch Cable Adjuster Nut

Support your Sportster on a motorcycle jack or secure the front wheel in a motorcycle chock or motorcycle clamp so the bike stands fully upright. Run your hand down the cable that attaches to the clutch housing until your fingers find a bellows-shaped, black, rubber boot. Pull this black boot up to expose a short nut called the cable adjuster nut and a long nut called the cable adjuster lock nut. Using two hands, slide an open-end wrench on both nuts and turn the nuts in opposite directions.

Loosen Clutch Cable

Remove the wrenches when the nuts are loose. Turn the small, clutch cable adjuster nut with your fingers until the nut is at the top of the threads and the clutch cable is completely slack. Pull the black sleeve on the top of the clutch cable near the clutch lever away from the clutch housing. Spray aerosol cable lubricant into the sleeve so it will drip down the length of the clutch cable.

Remove Derby Cover

Draw two lines across the derby cover that extend onto the primary cover, with a grease pencil or similar marker, so you will be able to return the derby cover to exactly the same position later. Remove the six Allen-head screws that hold the derby cover in the primary cover with an Allen socket and a socket wrench. Remove the cover. Remove the gasket and throw it away.

Adjust The Clutch

Separate the clutch plates by tightening the clutch adjusting screw, in the exact center of the clutch, with an Allen wrench. Back out the clutch adjusting screw at least four turns. Tighten the clutch adjusting screw slowly until it just bottoms out. Back out the clutch adjustment screw one-half to one full turn.

Replace Derby Cover

Put a new derby cover gasket on the inside of the derby cover so the red Harley logo on the gasket will face the clutch. Align the holes in the gasket and the cover. Replace the derby cover to the exact position it was in when you removed it, using the grease pencil marks as your guide. Replace and tighten all six derby cover screws with an Allen socket and a socket wrench.

Adjust Clutch Cable

Re-tighten the clutch cable adjusting nut until the clutch cable re-seats in the housing and there is no free play in the clutch lever at all. Loosen the clutch cable adjuster nut 1/2 turn at a time until there is 1/8 inch free play in the clutch lever before you feel tension. Immobilize the clutch cable adjuster nut with an open-end wrench and simultaneously tighten the cable adjuster lock nut with a second open-end wrench until the two nuts fit snugly together. Replace the clutch cable adjuster boot.

When the clutch pedal on your Honda Accord becomes soft, theres a good chance you are experiencing a faulty clutch master cylinder. If left unchecked at this point, it is only a matter of time before the master cylinder completely fails and you will be unable to shift your car. If you have a couple of hours and minimal tools, you can replace the clutch master cylinder at home.

Instructions

1

Disconnect the cable from the negative terminal on your cars battery. This is an essential first step in any car repair due to the risk of electrical shock.

2

Pull the cotter pin located about halfway up the clutch pedal assembly. While you are under the dashboard, you also need to remove the pedal pin from the yoke.

3

Locate the master cylinder on the engine compartment side of the firewall. Turn the bolts counterclockwise to remove them from the firewall so you can remove the faulty master cylinder.

4

Remove the hydraulic lines from the master cylinder. Make sure you have rags on your work surface so you minimize the mess from leaking clutch fluid.

5

Place the hydraulic lines on the new master cylinder and install the master cylinder onto the firewall. Turn the bolts clockwise to properly tighten them.

6

Insert the pedal pin into the yoke and the cotter pin into the clutch pedal assembly.

7

Fill the fluid reservoir with clutch fluid but do not put the cap on the reservoir. Press the clutch pedal several times to expel any air pockets from the hydraulic lines and top off the reservoir with more fluid. After you have bled the lines, replace the cap and tighten it.

8

Reconnect the battery to complete the repair process.