Required Tools and Supplies:
- Shop Rags
- Safety Glasses
- Nitrile Gloves
- Flat-Head Screwdriver or Pick
- Adjustable Wrench
- Moly Assembly Grease or All-Purpose Grease
- 10mm Socket
- 5mm Allen Socket
- 12mm Crowfoot Wrench
- Torque Wrench
- 12mm Wrench
Always wear safety glasses and nitrile gloves when servicing your Indian Motorcycle. To inspect and adjust the clutch lever on your FTR 1200, follow these steps:
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. Also inspect any exposed cable wire for fraying, kinks or corrosion. Replace any cables that are damaged, sticky or sluggish.
3. Move down to the primary cover and use an adjustable wrench 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.
4. On the left handlebar, use a flat-head screwdriver or pick to carefully remove the plastic cap from the pivot pin. Replace if any damage occurs.
5. Use a 10mm socket and 5mm Allen socket to unscrew the bottom hinge nut and remove the pivot pin.
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 until fully seated.
13. Reinstall the nut. Torque to 52 in-lbs (6 Nm).
14. Clean any residual grease off the handlebar and reinstall the pivot pin cap.
15. Rotate the clutch shaft arm and reconnect the clutch cable into the lower cable housing.
16. Measure the clutch lever free play between the clutch lever and the clutch lever mounting bracket. The clutch lever free play should be 0.019 to 0.059 inches (0.5 to 1.5 mm).
17. If adjustment is needed, the clutch cable adjuster nut is located along the lower right frame.
18. Loosen the lock nut with a 12mm wrench.
19. While holding the cable, use a 12mm wrench to turn the cable adjuster inward or outward until the clutch lever free play is set to specification.
20. While holding the adjuster, use a 12mm crowfoot wrench to torque the adjuster lock nut to 48 in-lbs (5.4 Nm).
21. Finish by verifying proper operation of the clutch. The engine should 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.