How to Adjust the Clutch Play on a Harley Ultra Classic

Harley-Davidson's flagship, the Ultra Classic, has the set the standard for touring motorcycles, providing comfortable ergonomics and protection from the elements with the Ultra Classic's trademark bat wing fairing. While many riders agree that the big Classic is perfect for swallowing hundreds of miles of open road, riding the bike is not a one-size-fits-all affair. Luckily, Harley-Davidson has designed the Ultra Classic's controls to be tailored to better suit the rider's size. The ability to adjusting the clutch lever's pull and engagement point is one example.

Difficulty:

Moderate

Instructions

Things You'll Need

• Motorcycle stand or lift (optional)
• Torx-27 socket
• Socket wrench
• Combination wrench set, standard (SAE)
• Primary fluid
• Towels or rags

1. • 1

     Park the motorcycle on a smooth, level surface. Turn the ignition switch to the "OFF" position.

   • 2

     Locate the cable adjuster on the clutch cable and twist clockwise until the clutch lever is at its loosest point and will move freely.

   • 3

     Remove the Derby Cover, the round plate on the primary cover, using a Torx-27 socket to unscrew the two mounting bolts. Set the derby cover aside.

   • 4

     Locate the clutch adjuster in the primary cover and loosen the clutch adjuster lock nut in the with the appropriately sized wrench, then unscrew it two complete turns out.

   • 5

     Reset the clutch cable's slack by turning the primary's clutch adjuster in until it is seated, or just touching the clutch release. The clutch lever should have very little slack, if any, at this time.

   • 6

     Loosen the clutch adjuster slowly, turning the adjuster a full turn from its seated position. This will free up the clutch lever for final adjustment.

   • 7

     Hold the clutch adjuster stationary and tighten the clutch adjuster lock nut.

   • 8

     Pull the clutch lever in and release several times to ensure that the cable is moving smoothly within the sleeve. Adjust the free play within the lever end of the cable by twisting the cable adjuster counterclockwise, leaving 1/16 inch to 1/8 inch of slack in the cable.

   • 9

     Wipe away any primary fluid that may have spilled and top off with fresh fluid before replacing the derby cover. Tighten the bolts with a Torx-27 socket.

Tips & Warnings

• For best results, adjust the clutch play when the bike is cold.

• If possible, place the bike on a stand or lift to provide additional stability.

• Consult a service manual for comprehensive details about this process, torque specifications and other requirements.