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ADJUSTING THE CLUTCH ON PANHEADS**


Foot Clutch Control Adjustment
Refer to Figure 65 for this procedure


1. Disengage the clutch by pushing the foot pedal all the way down (heel down). Check that the clutch lever just touches the transmission cover. If not, adjust the clutch lever as follows:
a. Loosen the clutch lever rod locknuts and turn the lever rod adjuster to lengthen or shorten the rod so that the rod just clears the foot pedal bearing cover. The rod should not be bent down by the bearing cover.
b. Tighten the locknut and recheck the clutch lever rod position.
2. Remove the screws securing the clutch adjustment cover and remove the cover.
3. Move the foot pedal to the fully engaged position (toe down).
4. Loosen the pushrod adjusting screw locknut. Then turn the pushrod adjusting screw so that the end of the clutch lever has approximately 1/8 in. (3.17 mm) free play before the clutch disengages. After making this adjustment, check the following:
a. On 1964 and earlier models, the clutch lever should contact the transmission case cover.
b. On 1965 models, there should be 1/4 in. (6.35 mm) clearance between the clutch lever and the starter drive housing.
5. Install all parts previously removed.
6. Test ride the bike. If the clutch slips after making this adjustment, perform the Clutch Spring Tension Adjustment.


Hand Clutch Booster Adjustment

Check the booster adjustment when the clutch hand lever operation becomes difficult, or if improper clutch operation is indicated. Refer to Figure 66 for this procedure.
1. Loosen the clutch lever rod locknut.
2. Adjust the clutch lever rod so that the clutch release lever has approximately 1/2 in. (12.7 mm) free movement. Move the lever forward until all slack in mechanism is taken up.
3. On 1964 and earlier models, the distance between the outer edge of the chamfered slot in lever and foot shifter housing on the transmission should be 4 1/4 in. (10.8 cm). On 1965 models, the distance between the chain housing and clutch lever rod should be 1/4 in. (6.35 mm).
4. Remove the clutch inspection cover or the chain cover.
5. Loosen the pushrod screw locknut.
6. Turn the pushrod adjusting screw as required to obtain the clearance specified in Step 3 for your model.
7. Tighten the locknut.
8. Loosen the control coil adjusting sleeve locknut.
9. Turn the adjusting sleeve until there is approximately I in. (25.4 mm) free play at the clutch hand lever.
10. Loosen the bellcrank adjusting screw locknut.
11. Turn the bellcrank adjusting screw until the bellcrank does not cross dead center when moved back and forth by hand.

NOTE
Dead center is indicated in Figure 66


12. Loosen the upper adjuster nut as far as it will go.
13. Turn the bellcrank adjusting screw a little a time until the bellcrank moves over dead center and remains in that position when released. Do not move bellcrank with clutch lever, move it by hand. Bell- crank should lock in position approximately 1/8 in. (3.17 mm) past dead center.
14. Tighten the bellcrank adjusting screw locknut.
15. Adjust the clutch lever rod so that there is 1/16 in. (1.58 mm) free movement of the clutch activating lever.
16. Tighten the clutch lever rod locknut.
17. Turn the control coil adjusting sleeve until there is 1/2 in. (12.7 mm) free movement of the clutch hand lever before clutch starts to disengage.
18. Tighten the control coil adjusting sleeve locknut.
19. Pull the clutch hand lever in fully. Then tighten the adjuster nut until the lever remains in. Next, slowly loosen the adjuster nut until the clutch hand lever returns to its released position.
20. Tighten the adjuster nut (13, Figure 66).
21. Test ride the bike. If the clutch slips after making this adjustment, perform the Clutch Spring Tension Adjustment in this chapter.

Clutch Spring Tension Adjustment

If the clutch slips after adjusting the foot or booster clutch assembly, you can increase spring tension on the 3 clutch springs up to a certain point.

NOTE
Do not use this adjustment procedure to compensate for worn or damaged parts

1. Remove the clutch inspection cover (Figure 65).
2. Measure the distance from the inner edge of the spring collar to the outer disc surface. Interpret results as follows:
a. If this distance is equal to or less than 7/8 in. (22.2 mm), the clutch springs are adjusted at their maximum setting. If the clutch is slipping, disassemble the clutch and inspect the plates for wear or oil contamination.
b. If this distance is greater than 7/8 in. (22.2 mm), perform Step 3.

NOTE
A new clutch is set up with a spring collar to outer disc surface distance of 31/32 in. (24.6 mm).

3. Tighten the 3 adjusting nuts 1/2 turn each. Then test the clutch by starting the engine and shifting the transmission into gear. Do not increase the spring tension so far that the measured distance is 7/8 in. (22.2 mm) or less.
4. Install the cover.


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**Copyright 1992 Intertec Publishing Corporation