SOURCE: adjust clutch cable
If you have a stock cable you need a 9/16 and a 1/2 in. wrench. about 1/2 way downn the cable there is a rubber boot. pull the rubber boot over the adjustment. Loosen the liock nut and adjust the cable so you have aprox 1/8 to 1/16 in. slack in the handle. Re tighten the lock nut and pull the rubber back over the adjustment.
SOURCE: The clutch adjustment screw on my 2005 Harley
call a harley shop im sure it should be torqued not just tightened
SOURCE: Will the wheels from a 2000 Harley-Davidson FXDX
Check to see if they both have the same diameter axle. Harley went from a 7/8 inch diameter axle to a 1 inch diameter axle sometime around that time period.
SOURCE: My 2000 FXDX Dyna Super Glide Sport has a rattling
Check your rotor out closely. Look for a crack in it that runs from one hole to another. The holes are for cooling purposes but if the rotor gets too hot for one reason or another, it'll crack. When it heats up from the braking action, metal one either side of the crack becomes uneven and causes a "click, click, click" noise.
If you don't find any crack, first off that's good, But, then you need a dial indicator to check for warpage of the rotor. Mount the dial indicator on the fork slider and the spin the wheel with the dial indicator on it. Anymore thans a few thousandths could cause the rattle by moving the caliper side to side.
The rotor caliper is mounted so that it will move side to side and the pads are mounted inside so that they "float". They have anti-rattle clips and springs to keep the noise down. Make sure all these parts are in there and positioned properly.
SOURCE: how to adjust clutch on a 2008 Harley Davidson
To adjust the clutch on your Big Twin, follow the clutch cable from the lever towards the engine until you come to the cable adjuster. Usually, it is located somewhere around the front downtubes of the frame. Slide the protective cover up or down to gain access to the adjuster. Loosen the lock nut and turn the adjuster barrel inwards to get a good amount of slack in the cable.
Next, take the derby cover off the primary cover. Inside, you'll see the clutch assembly with the clutch adjuster screw and lock nut in the center. Loosen the lock nut and turn the adjuster screw inwards (clockwise) until you feel a resistance. You may want to back it off and then turn it back in several times to get the feel of what you're doing. Do not force the screw as you will start to release the clutch. Turn it in until you just feel the resistance. Then, back the screw back out one half turn and lock the lock nut down. Replace the derby cover.
Then go back to the cable adjuster and turn the adjuster barrel outwards until you have about an eight inch of free travel in the clutch cable. Squeeze the lever and let it go. Pull on the cable and the housing should come out of the adjuster by about an eight inch. Lock the lock nut down and replace the protective cover.
Good Luck
Steve
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