Everything on bikes wears out with time even the mighty Harley-Davidson Big Twin clutch. The good news is the adjustment process is a simple DIY endeavor. I have a 2014 Harley-Davidson Low Rider but the process is similar for any Big Twin model you have.
Please note you shouldn’t adjust your clutch when you need to change your clutch plates. Big difference. If your Harley clutch plates are worn out get them replaced at a Harley-Davidson OEM parts dealer shop.
First, you have to remove the accordion-looking clutch cable adjuster cover that protects it from harsh elements. It’s located between the handlebars and the bottom part of the Big Twin frame. Finding it isn’t rocket science. Once you do, slide it up or down to see the clutch cable adjuster mechanism below it.
With the cover out, we now have to add some slack on the clutch cable. As a result, the cable housing will collapse removing any tension. This will make sure that the cable doesn’t affect the clutch while it’s being adjusted. When you are done it will be easy to press the clutch lever all the way till it bottoms-out as there will be no resistance.
Afterward, remove the clutch cover from the clutch. I promise it’s not as complicated as getting rid of Captain America’s suit. Just use a screwdriver to unscrew a few bolts on it. And, voila! Have a rug underneath your bike just in case some fluid leaks to the floor. Also, hold the clutch cover to prevent it from dropping on the floor. In order to adjust the clutch, you’ll have to loosen the jam nut that holds the clutch adjuster with a wrench.
Now onto adjusting the clutch. It’s pretty much straightforward. Simply use your fingers to make the clutch adjuster tight to the end. Don’t try to make it any tighter after it’s bottomed out. That’s it.
Now return everything back to factory settings. You might be too excited to show off this newly acquired skill that you forget to put the cover back on. You may realize that it’s a bit grabby but fret not, it’s just age catching up. Add a shot of silicone to the base and you give it a smoother ride.
You don’t have to visit a mechanic to do this. Save a few bucks for a rainy day. Just get your tool box and silicone and you are good to go.