All Harley clutch cables have adjustments. There should be only
about 1/8 inch play in the clutch lever. Follow the cable from the clutch lever
down to the Trans and about half way you will see a rubber boot. Under it you
will find the adjuster.-----------------
Also start by checking the shifter pawl adjustment/.Double check the spring on the pawl assembly as it may be broken or just worn out. Then look at your shift linkage from the lever all the way back. Be sure to lube it all and make sure it is not binding anywhere especially on the shaft where the lever attaches.And also make sure the shift levers are not loose on their shafts, especially the lever at the transmission. Then remove the top cover and check the pawl and spring.
---------------
The outer primary does nothing but support the starter shaft when engaged, it has nothing to do with holding the clutch basket in place. Can you pull/push the basket in and out by hand?-----------
Clutch basket is left thread.
When you have the cover off take the plugs out and with the bike on lift put in lash high gear and turn the rear wheel, does everything turn, rear belt, primary chain, motor. That will tell you really quick where the problem is located.--- The clutch basket should turn and primary chain should spin.But if rear tire not turning and primary chain not spinning.Then, Sounds like it's in the clutch basket.If the trans is in gear and the rear won't roll but the clutch basket turns and the primary chain isn't moving.--------- also get the clutch hub checked.If its cracked or worn out.-----This will help.thanks.Helpmech.
HANDLEBAR REMOVAL
1. Remove maxi-fuse.
REMOVAL
1. Remove left side saddlebag.
2. Gently pull side cover from frame downtubes (no tools
required).
3. Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
block cover.
4. Pull maxi-fuse from maxi-fuse holder.
2. Place blanket or protective cover over front of fuel tank to
protect against scratches or other damage.
FLHR/C/S:
Remove the handlebar clamp
(FLHR/C/S), NACELLE REMOVAL (FLHR/C), steps 1-
11, or NACELLE REMOVAL (FLHRS), steps 1-7.
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S) 2.31
WINDSHIELD REMOVAL
Standing at the front of the motorcycle,
use a finger to raise the wireform latch springs on
both sides of the windshield.
2. Gently pull on the top of the windshield until the upper
notches on the windshield brackets are free of the upper
grommets.
3. Carefully raise the windshield until the lower notches are
free of the lower grommets.
4. Remove windshield from motorcycle.
WINDSHIELD INSTALLATIONTo avoid scratching headlamp nacelle or auxiliary lamp
bracket, be sure that all four notches on the windshield
brackets are firmly seated on a rubber grommet.
1. Standing at the front of the motorcycle, carefully insert
the windshield brackets between the headlamp nacelle
and the auxiliary lamp bracket. Lower the windshield into
position until the lower notches on the windshield brackets
are seated on the lower grommets.
2. Gently push the top of the windshield toward the rear
until the upper notches fully engage the upper grommets.
3. Push down on the wireform latch springs, so that they
overhang the rubber grommets. If some adjustment is
necessary, loosen the retaining screws and rotate the
latch springs into the proper position.
NACELLE REMOVAL (FLHR/C)
1. Remove the windshield. See WINDSHIELD REMOVAL
on this page.
2. Remove the Phillips screw at the bottom of the headlamp
door (chrome ring). Remove the headlamp door.
3. Remove the eight Phillips screws to free the headlamp
housing from the headlamp nacelle.
FLTR:
Remove the instrument nacelle.
UPPER FAIRING/WINDSHIELD (FLTR), INSTRUMENT
NACELLE, REMOVAL.
FLHT/C/U:
Remove the fairing cap.
Remove the outer fairing as follows:
a. Standing at the front of the vehicle, use a T27 TORX
drive head to remove the three outer fairing screws
(with flat washers) just below the windshield.
b. Moving to the inner fairing side, remove the two fairing
screws just above the wind deflectors on the left
and right side.
c. Turn the handlebar to the right and remove the outer
fairing screw reaching in below the left side of the
fairing cap. Turn the handlebar to the left and
remove the fairing screw below the right side of the
fairing cap.
d. Tilting the outer fairing toward the front, squeeze the
two external tabs to remove the wire connector at
the back of the headlamp assembly.
e. Lift the fairing (with headlamp assembly) off the
motorcycle.Since the outer fairing screws hold the windshield in
place, the windshield may fall to the floor if not removed.
UPPER FAIRING/WINDSHIELD (FLHT/C/U), FAIRING
CAP, REMOVAL. Remove the radio (or storage box).
4. Remove the left and right handlebar switch controls..
5. Remove upper handlebar clamp screws (with flat washers).
Remove upper handlebar clamps and handlebar.
HANDLEBAR INSTALLATION
Just reverse for install. This is all from the maunual and I hope it helps you.
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