Tools and Supplies Required:
- 10mm Socket
- 13mm Wrench
- 14mm Wrench
- 14mm Crowfoot Wrench
- Torque Wrench
- Adjustable Wrench
- Flat-Head Screwdriver or Pick
- Moly Assembly Grease or All-Purpose Grease
- Shop Rags
- Safety Glasses
- Nitrile Gloves
1. Park the motorcycle on a flat, level surface and allow it to cool completely.
2. Inspect the entire length of the clutch cable for any damage to the external casing. Inspect any exposed cable wire for fraying, kinks or corrosion. Replace any cables that are damaged, sticky or sluggish.
3. Move down to the cable connection near the primary cover and slide the rubber protector boot away.
4. With a flat-head screwdriver, remove the lower cable E-clip.
5. Remove the cable guide fastener with a 10mm socket and set the guide aside.
6. Use an adjustable wrench with a shop rag to rotate the clutch shaft arm until the tension has been released from the cable. Rotate the cable barrel out of the clutch shaft arm and release the clutch shaft.
7. Pull the cable down and out of the mounting boss.
8. On the left handlebar, unscrew the bottom hinge nut with a 10mm socket.
9. Push the pivot pin upward and remove from the handlebar.
10. Remove the clutch lever and rotate the cable barrel out of the lever.
11. Remove any old grease and dirt from the lever, housing and cable ends.
12. Lubricate the clutch lever and pivot screw with moly assembly grease or all-purpose grease.
13. Apply a thin coating of all-purpose grease to both clutch cable ends. DO NOT lubricate between the cable and sheath.
14. Reinstall the clutch cable into the lever housing.
15. Install the clutch lever into the handlebar, and align the pivot pin hole.
16. Reinstall the pivot pin fully.
17. Reinstall the nut. Torque to 35 to 62 in-lbs (4 to 7 Nm).
18. Clean any residual grease off the handlebar.
19. Rotate the clutch shaft arm and reconnect the clutch cable into the lower cable housing.
20. Reinstall the lower cable guide fastener. Torque to 84 in-lbs (9 Nm).
21. Reinstall the E-clip and slide the rubber protector boot back into place.
22. Check that the cable is properly routed in the mounting boss and cable bracket.
23. Measure the clutch lever free play, between the clutch lever and the clutch lever mounting bracket. The free play should be between 0.5 to 1.55 mm (0.02-0.59 in).
24. If adjustment is needed, the clutch cable adjuster nut is located along the lower left frame. While holding the cable, slide the rubber protective boot away from the lock nut.
25. Loosen the lock nut with a 14mm wrench.
26. While holding the cable, use a 13mm wrench to turn the cable adjuster inward or outward until the clutch lever free play is set between 0.5 and 1.5 mm.
27. Once free play has been set, hold the adjuster and use a 14mm crowfoot wrench to tighten the lock nut. Torque to 48 in-lbs (5.4 Nm).
28. Re-secure the protective boot over the adjuster.
29. Verify proper operation of the clutch. Ensure the engine does not start with the clutch lever released and the bike in gear. Repeat this procedure as needed.
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.