How to Adjust the Clutch on a 2007 Harley Electra Glide

The clutch on a 2007 Harley-Davidson Electra-Glide (FLHTC) transmits power from the engine to the transmission input shaft through a series of splined clutch plates in the clutch pack. The drive plates (those made with friction material) are splined to the clutch shell, while the driven plates (steel plates with no friction material) are splined to the transmission input shaft. A diaphragm spring compresses the clutch pack, which clamps the clutch pack together, increasing friction and transmitting the engine power pulses. Proper clutch adjustment is crucial to proper clutch engagement and disengagement, vehicle control and the longevity of the clutch pack and throwout bearing. Perform a clutch adjustment after any clutch component is replaced, and then again 500 miles of service after the replacement is made.

Things You'll Need

• T27 Torx driver
• 1/2-inch open-end wrench
• 9/16-inch open-end wrench
• Wrench set
• Allen wrench set
• Pound-inch torque wrench
• Crow's foot set
• Shop rags
• New clutch inspection cover o-ring (if necessary)

Instructions

1. Park the motorcycle on firm, level ground. Have a helper hold the bike upright and level.

2. Loosen and remove the five inspection cover retaining screws with a T27 Torx driver.

3. Remove the inspection cover and o-ring. Use caution: do not allow debris to enter the primary chaincase through the open inspection hole.

4. Slide the rubber protector boot off of the clutch-cable adjuster located near the middle of the clutch cable. Take care to not damage the boot during this operation.

5. Hold the cable-adjuster body with a 1/2-inch open-end wrench, and loosen the jam-nut with a 9/16-inch open-end wrench.

6. Move the jam-nut away from the adjuster barrel and loosen the adjuster to create a large amount of free play in the clutch cable.

7. Loosen the clutch-adjuster locknut located in the center of the clutch pack with an open-end wrench.

8. Tighten the clutch-adjuster screw lightly with an Allen wrench then back the adjuster screw off one half to one full turn.

9. Hold the adjuster screw firmly in its position with the Allen wrench, and tighten the adjuster locknut to 72 to 120 pound-inches of torque with a pound-inch torque wrench and a crow's foot.

10. Squeeze and release the clutch lever to the limit of its maximum travel three times to ensure the clutch release mechanism is seated.

11. Rotate the clutch-cable adjuster barrel to extend the adjuster and remove the slack from the clutch cable.

12. Lightly pull the clutch-cable ferrule located at the end of the clutch cable where it enters the lever bracket. Loosen the clutch-cable adjuster barrel until there is 1/16- to 1/8-inch gap between the clutch-cable ferrule and the lever bracket.

13. Prevent the adjuster barrel from rotating with a 1/2-inch open-end wrench while tightening the clutch adjuster locknut with a 9/16-inch open-end wrench.

14. Slide the clutch-cable adjuster's protector boot back into position over the clutch-cable adjuster.

15. Remove the used inspection cover o-ring from the cover plate and inspect the o-ring for damage or wear. Replace if necessary.

16. Remove any primary chaincase lubricant from the inspection cover plate with a clean shop rag and install the o-ring. Ensure the o-ring nubs contact the ring groove walls.

17. Position the clutch's inspection cover plate over the inspection hole and install the five retainer screws. Tighten the retainer screws to 84 to 108 pound-inches of torque with a pound-inch torque wrench and a T27 Torx driver using a cross-pattern starting at the screw at the 12 o'clock position. Tighten the 12 o'clock screw, then the 7 o'clock screw, the 2 o'clock screw, the 10 o'clock screw and, lastly, the 5 o'clock screw.

18. Start the motorcycle. Engage and disengage the clutch to ensure proper operation before riding the motorcycle.

Tips & Warnings

• When using a crow's foot with a torque wrench, orient the crow's foot 90 degrees to the torque wrench handle. Otherwise, the crow's foot will artificially extend the length of the torque wrench and lead to a false reading.

• Failure to verify proper clutch operation after making the adjustment can lead to an unsafe riding condition caused by incomplete or improper clutch performance.

References

• "2007 FLT Models Service Manual"; Harley-Davidson Motor Company; 2007

Resources

• Harley-Davidson USA: Electra Glide
• "Federal Register"; Federal MV Safety Standards, Motorcycle Controls...; NHTSA; August 2005
• "Motorcycle Manual"; Commonwealth of Massachusetts, Registry of Motor Vehicles; 2010
• "Periodic MV Inspection Manual for Inspectors of Motorcycles"; State of Hawaii, Department of Transportation; August 2005