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Any ZillaCash you earn is automatically applied to the next purchase, so you can sit back, enjoy the ride and feel the savings blow through your hair. Item #: Clymer Manual Harley-Davidson XL883 / XL1200 Sportster 2004-2013 Clymer motorcycle repair manuals are written specifically for the do-it-yourself enthusiast.

From basic maintenance to troubleshooting to complete overhaul, Clymer manuals provide the information you need. The most important tool in your tool box may be your Clymer manual, get one today.

Includes color wiring diagrams. Note: It is always important to consult multiple sources with any questions when attempting to repair your own bike. Breaking things saves neither time or money!

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. 4565 Answers SOURCE: Get the bike standing as straight up as you can without danger of it falling over. This keeps any oil from running out of the primary. Remove the 'derby cover' from the outer primary cover giving you access to the clutch adjuster screw in the center of the clutch pressure plate in the primary. On the clutch cable, slide the rubber boot up or down to expose the adjuster in the cable. It should be on the down tubes of the frame under the fuel tanks.

Loosen the lock nut and screw the cable adjuster in as far as it will go thus shortening the cable. At the clutch back in the primary cover, you'll see a screw that takes a hex allen wrench with a lock nut on it in the center of the clutch pressure plate. Loosen the lock nut and back it off a bit.

Screw the screw inwards until you feel a resistance. You want to adjust this in until you feel a resistance, not to the point to where it starts releasing the clutch. Back the screw back out and do this enough times so that you know you are just going to the point of resistance. Turn the screw inward until you get to the point of resistance and then back the screw out 1/2 to 1 full turn. Lock the nut down. Now, adjust the clutch cable adjuster out making the cable longer You want to adjust the cable until you have about 1/8 inch freeplay at the clutch lever. Lock the cable lock nut and slide the rubber cover over the adjuster.

Test ride the bike. If the clutch does not engage exactly where you want it, use the cable adjuster to fine tune where the clutch engages by lengthing or shortening the cable. Posted on Oct 24, 2009. 4565 Answers SOURCE: To change the clutch cable on you '79 Sporty, you'll have to take the outer primary cover off. To do this, you'll have to drain the oil from the primary, take the left side foot peg off, and loosen the primary chain adjuster on the bottom side of the primary. Loosen the locknut and use an allen wrench or hex key to screw the adjuster bolt downward. If you need to know anything else, drop me a line at Then, remove the large 'plug' towards the rear of the cover.

Inside, you'll see something that looks like a nut but with no threads in it held in by a small spring. This the the lock nut, remove it. Below it is what looks like another nut with a slotted adjuster bolt sticking out. Remover the bolts from around the primary cover and break it loose from the engine.

While turning the adjuster screw at the rear of the cover inward, remove the cover. The cable connects to the cluch release mechanism.

1981 Harley Davidson Sportster Specs

By turning the 'link' downwards, you can disconnect it from the mechanism. Notice which way the 'link' in attached to the release mechanism. Take the 'link' off the end of the clutch cable. Break the lock nut loose at the threaded cable adjuster on the outside of the case and screw the adjuster all the way out of the primary cover.

Disconnect the cable at the handlebar lever and your cable is out. Reinstall the new cable in the reverse order. When replacing the outer primary cover, make sure you use a new gasket on the cover as well as on the foot peg boss. The 'foot peg boss gasket' is very important.

Sportster

You'll see an aluminum boss with a threaded rod sticking out of it that holds your left foot peg on. There is a round gasket that goes over this threaded rod and seals against the boss. If you leave this off, your bike will leak oil around this threaded rod when your foot peg goes on.

Parts For 1981 Harley Davidson

1981

Make sure you specifically ask for the 'foot peg boss gasket' when you buy the new primary gasket. It's just a round gasket a bit larger than a quarter. As you put the primary cover back on, there is a spring on the primary chain adjuster. Part of the spring is in the primary cover and the other part is in the engine. You'll see how it goes in.

1981

There is a large stud in that area that the outer primary cover slides up on. Adjust the tension on the primary chain by removing the 'plug' at the top of the primary cover. You want 3/4' to 7/8' up and down play in the chain with the engine cold. Woodward governor 505 manual. On the adjuster, as you're installing the outer cover, turn the ajuster screw back into the clutch release mechanism by turning the screw backwards.

Once you have the outer primary cover completely installed, you must adjust the release mechanism. Adjust the screw inwards until you feel a resistance, then back the screw off about a 1/4 to 1/2 turn, insert the 'lock nut' and spring, and install the 'plug'. Then, using the cable adjuster on the outside of the cover, adjust the cable.

Posted on Oct 26, 2009. Hi, Derek assuming you're talking about your 1981 Sportster and the engine is running and you pull the clutch lever and shift into 1st and let the clutch lever out and the bike does not move then you may have the following issues: 1. Clutch not engaging. The transmission is not in gear. There is a broken component inside the transmission. For more information about your issue and valuable 'FREE' downloads that you will need, please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.

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