What's WRONG with my Sportster Clutch?? - Iron 1200 Clutch Problems 

Ok, if your 1200 is like my 1200R, there are actually two clutch adjustment points. The cable you found. The other is inside the derby cover on the left side of the engine. Raise the bike on a jack so that it's level. Remove the 6 T27 screws that hold the cover on. Station an oil absorbent pad under the derby cover just in case. There is a small spring that should be in a detent in the center of the derby cover. Don't lose it! Put a dab of grease or Vaseline in the detent to keep the spring from falling off when you reinstall the derby cover. I replaced the T27 screws with stainless steel Allen bolts like those that hold most of the engine together. It makes the derby cover removal much easier. Now, you'll see a nut with a slotted screw in the center of the clutch. From the service manual: Slide hex lockplate with attached spring from flats of adjusting screw assembly. Turn adjusting screw counterclockwise until resistance is felt. Turn adjusting screw 1/4 turn clockwise. Reassemble. Adjust cable length until 1/8" of slack exists before resistance is felt at the lever. That's all, folks. Removing the derby cover is the best way to make sure the transmission has the proper oil level. The manual says a quart but it's more like a quart and a half.

Have you looked into the mechanism that actually pushes on the clutch basket when you acuate the lever? It's like a two section deal with 3 large steel balls inside it. I'm thinking that maybe the balls got stuck on the ramps or something, and eventually it would work loose and go back into place. You can lean the right bar end against a building or something to keep the bike in an upright position, or even leaning more to the right than the left and then remove the clutch cover and inspect this whole thing to see what is going on. Leaning it upright will insure you don't loose oil and you can check the level of the oil to see it is even with the bottom of the clutch spring. (the large round disc you can see)

nice road work repair sir. good to see ya in my home town streets 🤘🏽

You did he right thing. Roadside repairs teach you very much. Good luck!

I've had actually the same problem with my sportster xl 1200t superlow and the problem appears again and again. From the vibrations the clutch setting thread loose itself and can damage the entire clutch. After they've adjusted in the Harley Workshop I've put around a self-adhesive insulated band to keep everything in place and it works. But the clutch system by the sportster is quite old fashioned and very sensitive to vibrations. If you feel, the neutral comes hard, you should run directly to a workshop to set it right again before it damage the inside clutch rings.

On cable-operated clutches, they'll occasionally need adjustment like you described. There's usually 3 adjustment points: at the transmission, midpoint, and at the lever. A shop manual for your bike would be a good investment, or looking up the proper procedure online [like you did]. I had to do this to my 2 Kawasakis last year after oil changes. Got 'em adjusted right and they're in perfect operation now. I'd keep an eye on it, and if it gets worse again, you may want to have a deeper look at it or take it to a shop.

I actually had the same thing happen on my 08 1200 Custom & made the same adjustment you did & never had another issue, I'm assuming that the cable just stretched a little bit, if it seems ok I'd keep riding it if it were mine. If it happens again I'd get it looked at

looks fine, but on my kawasaki the clutch rod that goes down into the clutch housing messed up and wasnt pulling the pusher to release the clutch. but seems like yours is fine right now.

Love your content man! I’m from south Jersey and just got my 2021 1200xlns. I just started riding 2 weeks ago because of DMV. Anyways i took my bike to Cape May a few days ago and it was great. Hoping to have a great weather starting on the 25th this month so I can go check out asbury park and maybe even the Reading pagoda. I really like and enjoy your content as I discover local areas which I never have considered just driving around. I’m trying to get my break-in mileage before the riding season is over and I just got to 500 miles. Ride safe!

Had this happened to me many times. First the spring plate went to shreds, so I changed this to all plates. Second not having to much oil, then recently my clutch pawl has worn out so changed it.

Got the same matter ! I used to set the clutch as you did but without setting the cable. Did it come again ? It did on mine ! Any tips please ?

Hey y'all I have a 2000 buell. I have adjusted the clutch and and it still kinda pulls a little when I pull the lever all the way in in first gear. It still wants to pull just a little. At idle if I rev it just a tiny bit then it stops pulling untill I let the lever out. Idk it just kinda wants to move with the clutch in but just barely. Should I adjust it out under the derby cover a little more or is my cable too stretched help me out here please

I would check the cable to make sure you didn’t have any cable strands break. Disconnect the cable and pull it back and forth make sure it’s smooth. After that follow full clutch adjustment procedure. I know the older Sportsters you need to get to the clutch adjustment screw, set it per the instructions than adjust the cable than back to the clutch adjustment and do a final adjustment. Again this is on my 79 Sportster per my owners manual.

Nice work man. This is why it pays to have a small tool kit with you

How many miles on it? I have heard that the clutches have a tendency to start having issues around 15 to 20 thousand miles. The stock rivet plate starts to separate. Watched a couple of videos and read some forums about it. I’m going to replace my soon. I’ve adjusted mine every 5000 as I’ve noticed the fiction zone moves which is why I adjust it. I adjust it under the derby cover as well.

Sounds like the "grenade plate", mine went this spring with 11k on it. you can pull the cover off and probably see the rivets that popped. It's an alright job to do yourself you're going to have to buy some sockets and a clutch spring puller if you don't have them yet. With no tools it's like $250 job. If you can get the tools the clutch plates are just over $100

These things stretch and sometimes some of the cables break and it gets loose. Looks like it just stretched a bit though, you seems to be good now

Probably just the clutch cable stretching. Looks like you fixed the problem.

Clutch cables do stretch. I've adjusted mine not too long ago.

If that doesn’t work your clutch plates are shot. Just changed mine to screaming eagle

My bike did the same Thang

all issues can be summed up by one statement....It's a Harley

The bigger issue that you need to look into - new bike time. lol jk. Also, new helmet?

Sorry never happened to me so I can't offer any suggestions.

Stock sportster clutch baskets are not every good.

My 2023 street bob is doing this started yesterday took it in they told me bolt came loose and they fixed it and dropped the bike off today I went on ride when I got home to make sure it rides good and it happened to me in 5th gear too and after I test ride it its fuckn mush again and they just fixed it today smdh it's a brand new bike 2000 miles and they just did service I don't know wtf is going on either