Always wear safety glasses and nitrile gloves when servicing your Indian Motorcycle. To properly maintain and adjust the clutch lever on your Indian Challenger, follow these steps:
1. Park the motorcycle on a flat, level surface and allow the vehicle to cool completely.
2. Inspect the entire length of the clutch cable for any damage, fraying or kinks to the external casing or the cable wire. Replace any cables that are damaged, sticky or sluggish.
3. Next, use an adjustable wrench to rotate the clutch shaft arm until the tension has been released from the cable. Release the cable barrel from the shaft arm and carefully release the clutch shaft.
4. On the left handlebar, unscrew the bottom hinge nut with a 10mm socket.
5. Then push the pivot pin upward and remove from the handlebar.
6. Remove the clutch lever and rotate the cable barrel out of the lever.
7. Remove any old grease and dirt from the lever, housing and cable ends.
8. Lubricate the clutch lever and pivot screw with moly assembly grease or all-purpose grease.
9. Also apply a thin coating of all-purpose grease to both clutch cable ends. DO NOT lubricate between the cable and sheath.
10. Reinstall the clutch cable into the lever housing.
11. Install the clutch lever into the handlebar and align the pivot pin hole.
12. Reinstall the pivot pin fully.
13. Then reinstall the nut and tighten until fully seated.
14. Clean any residual grease off the handlebar.
15. Carefully rotate the clutch shaft arm and reconnect the clutch cable.
16. Next, measure the clutch lever free play between the clutch lever and the clutch lever mounting bracket. Specification: 0.5 to 1.5 mm (.019 to 0.59 inches).
17. If adjustment is needed, loosen the clutch cable jam nut with a 12mm wrench.
18. Turn the cable adjuster inward or outward with a 12mm wrench until the clutch lever free play is set to specification.
19. While holding the adjuster, tighten the clutch cable jam nut securely with a 12mm Crowfoot wrench. Torque to 48 in-lbs (5.4 Nm).
20. Finish by verifying proper operation of the clutch. Repeat as needed. The engine should not start with the clutch lever released.
For more information, see your authorized Indian Motorcycle Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.