FASTENER | TORQUE VALUE | |
Clutch inspection cover screws | 90-120 in·lbs | 10.3-13.6 Nm |
Clutch cable adjuster jamnut | 120 in·lbs | 13.6 Nm |
Release the clutch cable tension
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
2. XL Models: See Figure 1-24. Remove cable adjuster from the frame retaining clips.
![](https://motoinstruction.ru/img/harley/12/117553.jpg)
Figure 1-24. Clutch cable adjuster location: XL Models
3. See Figure 1-25. Pull the boot (1) away from the cable adjuster (2).
![](https://motoinstruction.ru/img/harley/12/117554.jpg)
Figure 1-25. Clutch Cable Adjuster: 1. Rubber boot; 2. Cable adjuster; 3. Jamnut; 4. Cable end
4. Loosen the jamnut (3).
5. Turn the adjuster to loosen the clutch cable at the hand lever.
Clutch adjustment
1. Access the clutch inspection cover:
- a. XL Models with Mid-mount Controls: Remove the clutch side rider footrest and mounting bracket assembly. See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
- b. XR1200X: Remove the clutch side rider footrest and shifter mounting bracket and a shift linkage pivot bolt. See 2.42 RIDER FOOT CONTROLS: XR 1200X.
2. Remove the clutch inspection cover. Discard the quad ring.
3. See Figure 1-26. Remove the hex lockplate with the spring (1) from the clutch adjusting screw (2).
![](https://motoinstruction.ru/img/harley/12/117555.jpg)
Figure 1-26. Clutch Adjustment Screw: 1. Hex lockplate and spring; 2. Adjusting screw
4. Turn the adjusting screw counterclockwise until resistance is felt and then turn the adjusting screw clockwise 1/4 turn.
5. Install the hex lockplate with the spring and turn the adjusting screw clockwise to fit the lockplate onto the flats of the adjusting screw.
6. Install the clutch inspection cover.
- a. Install a new quad ring in the primary cover.
- b. Install the inspection cover.
- c. Install the screws and tighten in a cross pattern to 90120 in·lbs (10.3-13.6 Nm).
7. Install the foot controls:
- a. XL Models with Mid-mount Controls: Install the footrest and mounting bracket. See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
- b. XR 1200X: Install the rider footrest and shifter mounting bracket and shift linkage. See 2.42 RIDER FOOT CONTROLS: XR 1200X.
Lever free play
1. Turn the adjuster away from the jamnut until there is no slack in the cable at the clutch lever.
2. See Figure 1-27. Pull the clutch cable ferrule (2) away from the clutch lever bracket (3) and measure the free Play (4).
![](https://motoinstruction.ru/img/harley/12/117556.jpg)
Figure 1-27. Clutch Free Play Adjustment: 1. Clutch cable; 2. Cable ferrule; 3. Clutch lever bracket; 4. 1/16-1/8 in (1.6-3.2 mm) free play
3. Adjust to specification. Refer to Table 1-11.
4. Tighten the jamnut to 120 in·lbs (13.6 Nm).
5. Pull the rubber boot over the cable adjuster.
6. XL Models: Secure the cable in the cable retainers.
7. Install main fuse.
Table 1-11. Clutch lever free play specifications
FREE PLAY | in | mm |
Measurement | 1/16-1/8 | 1.6-3.2 |