DOC HARLEY: EASIEST CLUTCH CABLE ADJUSTMENT
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- Опубліковано 15 кві 2020
- Doc Harley from the Service Clinic at Low Country Harley-Davidson to help you with the health of your motorcycle! This week he talks about the process for a clutch cable adjustment on a Softail with a Milwaukee-Eight.
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Doc Harley is a motorcycle technician at Low Country Harley-Davidson with over thirty years working on motorcycles. Over the years at the dealership he has worked on Harley-Davidson, Buell, and Triumph motorcycles with a few other brands here and there from trade-ins. There are thousands of how-to videos out on UA-cam and other websites across the world. Doc’s goal is to help solve problems that people run into when using their service manual, share insights only found as a certified Harley® technician, and some of the tips he’s picked up over the years.
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I have always hated clutch lever adjustments. So when I had way to much free play on my 2019 heritage I was dreading having to adjust it. Watched your video twice and did the adjustment in less time that it took to watch the video once. What on earth possessed Harley Davidson to come up with something so simple , it’s so out of character for them! Great video thanks!
You just saved my bacon with this video,... I moved the clutch cable to the front... pushed the clips in and had all that freeplay... I needed the second step - so easy - THANK YOU SIR!
thank you! I was having so much trouble finding neutral and felt like an idiot every time I parked my bike. I followed this video and now my clutch is perfectly adjusted.
Agreed Doc! That is much quicker/easier than the traditional method. Praise the motor company for continuous improvements.
This video helped a ton! Had a lot of dead space in my clutch handle, this cleared it right up. Thank you!
Wow! This is so much easier than I thought it'd be. Thanks for the video!
Thank you so much for showing me this! I noticed on my ride home that my clutch lever was loose. Yay for me for having the exact bike that you are working on! :D
Doc Harley... That is an awesome way to adjust the clutch cable. I don't like to see plastic but it is what it is. They should have made it out of metal... Thanks for sharing it with us......
I took the Mrs’ Heritage out for about an hour yesterday. So much lighter than my Ultra Limited. Even with just the 107, it has a higher power to weight ratio than my 114. Some day I’ll be retired and I’ll be able to do lots of demo rides, too! That Indian seems very similar to a Street Bob, but with smaller bars. Nice little cruiser.
I just followed your instructions and swapped out the HD levers for the 1FINGER fully adjustable levers on my 2021 Softail Standard. Couldn't believe how easy it was. Thanks so much Doc!!!
Glad we could help….Doc
In theory, this is a good idea. But on my '21 RGS it doesn't work. After compressing the spring fully and ensuring the cable ferrule is properly seated in the clutch perch and the clutch lever is full forward, when I remove the red lock clip and release the spring tension then reinsert the red the red lock clip, I end up with inconsistent clutch lever play. The gap at the clutch perch obtained by pulling on the clutch cable will always be more than the 1/8" max allowable gap (sometimes up to 5/16"). The only way I can get the proper adjustment is to release the spring tension and then manually try to extend the spring further while installing the red lock clip. This new design would've been a whole lot better if the red lock clip was threaded to facilitate "fine" adjustment by rotating it around the threaded end of the cable (kind of like the old school design!!!).
I am having the same issue on my 21 RGS and your comment just helped me solve that i thought i needed to pull the derby cover off and do a adjustment but i did not want to go that far it seems to me that the spring isnt strong enough or the cable needs a major adjustment. After this i might just swap the whole OEM cable for a nut and bolt old school adjuster and braided cables all the way around.
Great job, Doc. Always enjoy your videos. Keep up the stellar content.
Thats amazing Doc thanks for making it keep safe.
wow that was so cool. you are right so much easier. I have been wanting to replace the levers and have been hesitant. cool.
You have no idea, or maybe you do which is why you make these videos, but you just made me feel so much better about my situation! After a long ride my cable lever was loose as heck. I thought I was going to have to take it to a shop. Nope, not at all. After watching this video and 5 minutes in my garage, everything is back to smooth!!!!!
Glad I could help….Doc
Thanks that was easy to do ...great video...
Thanks.
Thanks Doc!
Thank you Doc.
Thank You, Sir!
Thanks Doc! Great info!
Thanks for another helpful video
FINALLY DOC.... I had been waiting for this video for years.... I have to say, Im a marine diesel mechanic (not your average boat... I mean BIG diesels) and I had seen a lot of cool and unusual things... but this clutch system has to be the best thing a Harley engineer has EVERRRRR invented/designed .... ohhh my freaking God... its practically self adjusted!!!!.................(this made my day) ...Thanks Doc.
my only note to Harley on this... is that it would it be better if it was completely made out of metal and not plastic... i hope that would be an upgrade down the line
@@ARMASARMY yeah mate and retrofit to fit other models and years
I'm sure there's a back yard mechanic out there somewhere copying this
Wow, that’s a lot nicer than the way I had to do it on my 2009 Heritage. Thanks
The only think I hate about the clutch cable adjustment on the M8 softail is you can’t set it to personal preference on the lever.
Thank you Doc
You are very welcome...Doc
😂 watching this last night I had too much slack and did exactly what you showed us fixed it perfectly thanks Doc
That just answered my question if we can do just that. Which means it is ok to adjust without removing the derby cover.
You are really good that’s why I follow you thank you
Doc Harley you saved me again
Thanks again doc. You saved me once again. Went to the dealership for an oil change, the clutch was feeling a little different. I asked them to give it a quick check as I'm going in a big ride tomorrow. Get it back, and there's no friction zone. It only grabs in the last 2mm as I release it. I rode it home like that, watched your video, now it's perfect. How could a dealership mess that up so bad? I called and they said "the tech took all the play out of the cable". The clutch felt so tight.
With new technology new learning curve for new techs. Cut him some “slack” 😆
Thanks bro, you’re the greatest
I always heed the words of the 'Doc'. Great advice given in a very understandable manner 10/10 sir.
Thank you kindly….Doc
You are a darn good fella Doc!
I appreciate your time and support….Doc
Thaks Doc. Simplicity itself. I'll have to look for the 5,000 mile adjustment video.
DED1939 John Maxwell has a video on it if you want to check him out
This was very, very helpful! Thank you! 🙏
Glad it was helpful….Doc
Life saver! Best teacher in the world 👊
Thank you for the kind words...Thank you for watching...Doc
You just saved me SO MUCH time. Thank you.
Thanks for tuning it....Doc
Brilliant thanks 👍🏻
Great Video , I could do the old type with my eyes closed . Then I looked at my new 22 Street Bob and consulted with the shop manual and still really didn’t understand it . Then I thought of Doc ! Thanks again for your great informative Videos !
Thanks Old Rover…..Doc
I adjusted the clutch on my 06’ E Glide twice in 12 years and 144K. I only adjusted twice because I didn’t like the way I did it the first time. Mech re installed clutch discs with 140K plus due to lack of wear. However some people can burn a clutch up in under 15K. To each their own
03 Lowrider. adjusted the cable twice and have not adjusted the clutch itself. 70,500 on it Yes different riding styles , to each their own
Great vid doc..All the best from 🇨🇦 stay safe and well. 🇨🇦/🇺🇸!!!!!!
Thank you, Doc! Bought the manual and your video makes it so clear!
Another Great Video...
Hi Doc, I'm the owner of a new, (to me), 2004 Heritage Softail.
It had 11,500 miles on it when I got it... Now, after a month, it's got about 11,800 miles.
I know very little about HDs...
And the stories are aplenty, about the one I own, in a spectrum of years, that offer failing cam chain tensioners, bad cam bearings, cam and tappet rollers, that are too soft on the surface glaze.
Cam plates that either succumb to wear, or the lack of a bronze bushing, that allows crank 'runout,' to simply eat the aluminum plate. Or the runout causes the rotors in the oil pump to strike the inner walls of the pump housing, and destrioy the oil pump, and/ or more of the engine, from metal in the oilflow...
On and on, I hear the bad things that are exiting the HD factory... Gone are the days, when a father could offer his son the 'hand-me-down,' car or motorcycle.
Gone are the days when an American manufacturer, would stand behind their product, until the original buyer was dead, and maybe even longer!
Maybe you're old enough to understand what I mean...
I just wanted to thank you, for your excellence in the videos you produce for YT. Yourself, Twin Pro, J&P, Darkhorse, S&S, and others, give great info, tech tips, wrenching advice and more, all free to us less educated in all things mechanical...
I told the HD dealership, that I could have went across the street, to the Yamaha dealer, and invested in a jap bike, and never gave it another thought...
But I wanted to experience the HD world, that's always been around me, and be a part of the HD family...
I was really sad, when I went in and saw, in all the patches, decals, signs and apparel, there was no longer an American flag in the mix... Not a single American flag, in a shop full of Harleys, that were supposed to be an 'American Icon...'
I was wondering...
Is Harley Davidson still even an American company?
Or are they owned by foreign nationals, like Budweiser, or Smithfield Hams?
Hi Doc!
Thanks for another great instructive video.
Can I suggest a video topic? Speedometers.
Let me explain... I have a 1998 FLSTS Heritage Springer. The trouble is that the speedometer (well, the tacho bit anyway... the digitised/LED bar - y’know, the old-style grey-background LED with the black digital numerals) has been giving me trouble for quite a while now.
The black numerals are faded to the point of non-existence. After a half-hour (getting longer all the time) of riding, the numerals gradually start to reappear... not greatly but just about readable. This has been getting worse all the time and taking a longer and longer warm-up to be able to see the numerals.
What can be done about this?
This is a very Kick-Ass piece of engineering. It reminds me of how the shifting linkage adjustment is done on a manual transmission of 2001 VW Beetle. You put this metal pin in a slot on the shifter while it's in neutral, that holds it in place. Under the hood, grab one of the two cables and pull back a fitting and release it. Then you put the shifter in reverse, pin it, and do the same with the other cable. It also happened to be the most impressive thing on the whole car.
Thanks for sharing your history...Doc
You’re the best!!!
Video was just what I needed to change the clutch lever!!
Glad it helped, thanks for watching...Doc
@@LowCountryHarleyDavidson please do a video one how to change the handgrips for an fxlrst
THANK YOUUUUUU
Doc I'm waiting on parts for a engine rebuild it's coming up too 3 months.
What's up Doc with Harley parts?
Getting that should have bought a Honda feeling. So what's the hold up?
Thanks.
I find it interesting to do a major clutch adjustment after 5k miles. I believe I heard EVERY 5k, not just the initial. I have ridden 3k mile weekends! I have 40k+ miles on my bike with no apparent adjustment/change in lever pull/Freeplay. I gotta wonder if this scheduled maintenance is for all the fools that don't know how to use a clutch. You know, all the fools that can only pull away by reving the hell out of a long stroke torque monster to pull away from a stop sign. Yeah, this is a dig on many riders. If you ride like this, you are missing the beauty of a Harley; all of that low end torque. Ride safe all, and please ride. We the riders need to promote the activity. Doc, I appreciate your videos, thank you!
Dave Shoemaker If you ride “normal” then you don’t hv to do the major clutch adjustment as often. This “cable” clutch adjustment is just that, to tighten or add play to the CABLE only, not really the clutch. If you do your own maintenance, and change the primary fluid, you can easily just adjust the clutch nut/screw since you will have the derby cover off anyways. I used to do it every time it was off, but realized it really didn’t need any adjustment, so now I do it every other year or two. Also, I would prefer the older metal (two nut) adjustment on the cable vs this plastic and spring version, as you can adjust the cable play more to your liking with the metal version. Just my opinion.
Thanks Doc, I was wondering about this. My 2023 FLH seems to not have enough freeplay, maybe a 1/16. I would like more. It seems to me that the release bearing [throwout] never gets a break, and I would like initial engagement to start to occur closer to the bars. Any way to correct this?
Hey Doc! Can you show how to remove the Brake lever? I heard about a small piece underneath it that can be broken if not done properly. Thanks a lot for the good Videos keep it up!
my brand new 21 FLHTP has zero slack in the clutch cable. kinda upset about it. I've put a few hundred miles on it and finally decided to check to see if it's supposed to have free play.
Thank U
Welcome….Doc
ok i watched it many times but I cant figure out how still to remove the slack of my clutch lever cable, I only understand is how to replace the lever
That's because he didn't make any adjustment, he just released the clutch cable and then put the tension back on, so the heading should read "how to replace a clutch lever"...
This is all I did for my clutch cable and it adjusted fine.
Can you adjust your engagement point though that adjustment?
Hey Doc should i adjust when engine is cold or hot ?
Hey Doc. Are you going to do a vid on the 131"?
Too easy man thank you
Thanks for watching and posting….Doc
Hi doc, how about a how-to properly adjust the primary chain on a HD sportster, 2011 , xr1200x, too many iffy methods , needs your savvy . Cheers
What is the best way to fix your drain plug oils strip
Unrelated question Doc, but what is the difference between EG 4 speed front ends and EG 5 speed front ends. I'm told that a headlight nacelle/cowl won't fit my '87 EG 5 speed, but my '96 EG 5 speed had the same unit I want for my '87. HELP!!!
Great video Doc! Does H-D make the M-8 clutch cable for older Harleys? Thank you 🇺🇸
Not at this time…Doc
Am i the only one who missed the part where he adjust the clutch cable? push red pin, collaps the spring, lock back again the red pin, and go chang/clean your lever, go back to your adjuster and put back again the tension of the spring. aren’t you’re suppose to turn something on the adjuster? the top piece of the adjustor? turn when lock? or when pin is pushed out?
Yeah I didn't get it either.. Unless it's some fancy self adjusting deal
I don't have this model, but the point of the video (as I saw it) was to show that it is easy because the spring adjusts the cable housing length.
Dave Shoemaker you’re actually right. it’s not a how to adjust your cable. I have the same adjustor and couldn’t find a how to when i was doing my bars but i figured it out.
Hi Doc
I enjoy your very informative videos. Could you do a clutch cable video for a 2021 Road / Street Glide as the cable is hidden on the left side.
Thanks for the request...Doc
If after doing what you just showed us and the gap is greater than 1/8 inch, would be good to show how to do the fix adjustment under the derby cover. If the cable is OK, after loosening the lock nut, can you do the fix by just turning the adjustment screw (in or out?) slightly without going through the 'feel' process, then having back the screw out slightly? What about adjusting the cable/clutch screw under the derby cover so that the clutch lever friction point can be set where the rider prefers.
I suggest leaving the screw adjustment behind the derby at factory spec. The 3/4 turn out is for expansion at operating temp. Make this smaller than 1/2" the clutch could slip. This doesn't have influence on friction point. Cable construction (Teflaw Inner Sleeve) type oil used in primary. Condition of lever lube points, choice of lever. Ball and ramp release mechanism (OEM vs. Meuler) all influence how a clutch feels. Thanks ~ Doc
@@LowCountryHarleyDavidson Not sure you explained how to change the friction point on OEM clutch lever operation. The friction point on my FXLR was just back a little from pulling in the lever, but I wanted it further back. As OEM HD clutch levers are still from the last century, I purchased lever with a dial adjustment on top to move the friction point where I want it, not where HD wants it.
Don't let the dealer do it... that'll be a $200 clutch adjustment Lol
That's because what he's showing you here is just a temporary fix between service intervals. At each 5K service interval someone has to go in and adjust the clutch plate again. It's not that difficult but still needs to be done.
Great video as always Doc! Hey, I have a 2005 Roadking...can you just buy a post 2008 clutch cable like the one you show and convert it to fit my bike?
Might be possible…..Doc
Now please tell me that will retrofit to evo 1340! Yeah we still ride ‘em!
Hello and thank you for the video. I have a 2021 Road Glide Special and when I loosen the red clip and compress the spring and snap the red clip back in, it does not hold the spring just pops back up and I cant make adjustments. Any help would be appreciated.
Take your bike to your dealer. This should be covered under warrenty.
Doc - could you do a video on the more major clutch adjustment behind the derby cover? There are video's online for this, but a clear and consise one done by you would be good.
Thanks
Matt, Essex - United Kingdom
ua-cam.com/video/IyW6oi6e_U8/v-deo.htmlsi=XMLv5netbtFtIvWG
Doc, how to remove and replace the cable?
Doc, the clutch lever on my 2022 Fatboy, appears to be properly adjusted. It’s really hard to push bike with clutch lever pulled in while in gear. Should it be? Is “drag” normal, or should it push the same as if it were in neutral? 3700 miles on bike. Thanks. Great videos.
There will be some drag. Put in gear has the Constant mesh transmission turning all the gears with the rear wheel, belt and front pulley. For an example, bike started in the morning, clutch in, Shift into first- clunk! All gears turning….Doc
Great vid! Does Harley have an upgrade clutch for those of us who do a fair amount of riding in first gear in the “Gray Area” (like police motor training)? I have a 2016 RoadGlide and get stuck in heavy traffic (and yes, I’m a retired motor cop). Keep those vids coming. You are a natural teacher.
May I suggest a Screamin' Eagle variable pressure clutch? It provides smoother clutch disengagement at lower speeds. Use your stock clutch diaphragm. Thanks ~ Doc
Go with a DP clutch. The feel is a lot better than the Screaming eagle clutch and a lot less money.
So I just changed my levers on my street glide st. I thought I had to pop the red clip put like you did And then spin the yellow tube to release the slack. But it didn't do it, now I spun it a ton but don't know where it was before, how do I re adjust it correct?
I have reread the instructions. There is not "spinning" Push the red tab out, let the spring push the top cable up. Yes sometimes this needs a little help by pulling on the upper cable. push the red tab in to lock the adjustment. check the clutch lever for correct free play.....Doc
Hey Doc sorry I’m on an older video. I have a 2011 Dyna Fat Bob. Sometimes it shifts smooth. Other times it takes a bit more push. Is it overfilled with oil? Or something else? Thanks
It might be needing lube and readjustment. Or something is starting to come loose🤷♂️…..Doc
Doc H, great video for servicing clutch lever play. any chance an earlier model Jam-Nut clutch cable could be installed? just an Ol' Dinosaur adjusting clutch play since 2004 on '98 FXDWG/'01 FLSTC/Buell P2 [hey, how'd THAT get in here??]. just prefer "the ol' waya doin' things" if possible. oh yeh, setting clutch plates no worries... just like i always dunnit. thanx. marklewis
Anything is possible, I have not tried…Doc
good day Doc! can you tell me how to adjust my clutch cable..lol i just watched your vid on this and not sure if that is what i need, my clutch lever has to come all the way out before it will engage with 1st gear. i would like it to engage with gear when my lever is 1/2 to 3/4 out..(3/4 out would be perfect!) i recently purchased 2019 Road king and is all new to me! road a 08 fat boy and the clutch lever was perfect..can you help? thank you! Pete
Email me….Doc
Curious how to adjust the friction zone on low rider st I feel it’s so close to all the way to the grip
Harley-Davidson really does not have adjustable directions. Suggest adjustable levers so You can set to your liking….Doc
Lubing the cable is more fun but well worth it. You can pull it with one finger afterwards. You'll need a better than Harbor Freight snap ring pliers though. That pesky ring has tiny holes. Make sure to have a spare on hand. If not you'll surely lose it.
You are dam right about that. Lol. Even with a good set of snap ring pliers, the holes are so small, that you are guaranteed to launch them into the same dimension that the mate to your socks end up when the dryer is done. Lol. Get a few extra
Any retro fit kits for 16 dynas? Thanks doc 👍
Great question. Harley-Davidson does not supply this information. This could be a service clinic project with Doc in the future. Thanks for the idea. ~ Doc
I have to apologize for asking this question :) do you have any idea where I can buy new spokes for my Sportster Nightster 2008 back wheel...or maybe I should change the spokes of the 2 wheels...? thank you in advance
Go online to Dennis Kirk. Great company, lots of Harley parts, awesome website. I've been doing business with them for years, always treat me right
Is the inside derby cover clutch adjustment process same for my 22 FLTRK (no service manuel yet) as it is for my 2010 FLSTC. ?
Thanks
Yes the same
I gota get across country just to meet you and Low Country HD ! Thanks
Doc, I have have limited iseage in my left hand due to a stroke and am researching ways to deduce the cluch pul with my left hand l. I have added silicontothe cable already. Is there a way to make it any easier? Thank you for any help that you can offer.
Not knowing the model or year, I suggest a Mueller ball and ramp assembly and an adjustable lever...Doc
Installed a longer clutch cable and ape hangers. Tried everything to get some slack to connect the lever , but barely any slack. What am I missing?
It could be as easy as when you installed the new cable the ball and ramp assembly rotated forward. Take the cable out of the lever. Back the cable adjuster back to zero adjustment. Push the inner cable in as far as it will go. You can try to look in the transmission filler hole to see if the end of the cable is all the way back of the cover. Sometimes it helps to back off the adjuster screw at the clutch. If this does not work, you might have the wrong year cable. Thanks ~ Doc
DOC, I really enjoy your videos! A questions about levers and cables. I had the dealership move my handle bars forward some, but now I have to reach over the top to reach my clutch and brake levers, can these be rotated back some so I don't have to reach over the top so much? Thanks for any info.
It depends on your model. RG have pins so not much rotation available. And the older the Harley the more likely some adjustments can be made. Please take your bike back to the dealer and ask...Doc
@@LowCountryHarleyDavidson Thanks I have 2014 Tri Glide, forgot to mention that. Idea why don't you write a short pamphlet 25, 50 Things You Can Do to Make Your Harley Last Longer. NOTE: This is just the idea, number could be anything or different title. Pictures with your UA-cam links. I would buy it for sure!
Hi Doc
Do you do they make a cable like this for years prior ?
NO I do not know of a cable like this for early years....Doc
Listen I'm a 55 year old boy from Chicago (but I reject city type life and everyone assumes I'm from the country) oh I started riding a mini bike when I was 4 years old had a sportster at 17 and bla bla bla 7 harleys later I'm a old man and I love to fo the work on my bike but alot of years I was a Union highrise carpenter building concrete forms allday so plenty of guys have worked on my bikes in the Chicago Harley Davidson service dept. and all of them were good mechanics but come on fellas???? Doc Harley is the top dog of all Harley mechanics!!!! No doubt about it!!!! Keep those wrenches swinging DOC!!!! You know your shit!!!!!
Carl your words are very kind. There are good Master Techs in the a Windy City and all over America. We keep the Eagle flying. Thanks ~ Doc
What happens if after performing this procedure, including adjustment of the actual clutch plates ,there is still excessive freeplay?
Something is not right. A bearing might be worn out….Doc
Hey doc How about a video on spark plug reading
A lost art my friend. Also very hard to apply to modern engines due to lead-free ethanol fuels, fuel injection efficiency and traffic. Thanks ~ Doc
I'm waiting 2 months so far for top end engine rebuild under warranty for my 2019 Harley Davidson.
Dealership has said there's no E T A or any light at the end of the tunnel blah blah.
Why have I waited 2 months going on 3 with no end insight?
Don't hide behind the Coronavirus my bike required work done under warranty before the coronavirus popped up.
Please please explain Doc, you're in the know.
Cheers in advance if you can be bothered explaining to me..
What does your rebuild have anything to do with a clutch adjustment video? Doc is great at supplying videos that help the general riding community. Take your rebuild complaint back to the dealer and/or factory.
👍
I like you 👍
Do a video on what happens when that plastic part breaks. Throw it away and get the fat baggers adjuster.
Thanks for sharing….Doc
Hi Doc,
Each time I shift gears. It sounds like I hammering a nail. Secondly, I cannot find neutral while parking. What needs to fixed?
Thanks.
Too many variables to make a suggestion. If anyone is going to ask a question like this, I at least have to know: Year, Model, mileage, any modification, are you new to this bike or have owned it for years, Every service done? By you or dealer? Have you tried a dealer and they can’t repair it? Have you called Harley-Davidson Customer Service? Do you own tools and Service Manual? Thanks ~ Doc
@@LowCountryHarleyDavidson
2007 Heritage Classic
30k miles
I bought it few months ago. I don't know if previous owner took it to the dealer for service. I just did change engine, transmission & primary oil. I have an appointment with the tune up guy next month.
2018 sport glide that has very little to zero Friction Zone. 8k and every time it's been in the dealer (4 times) I have them adjust clutch, 100 miles later zero friction zone.
What could be the issue here? Could it be they are not Adjusting in in the primary? Only doing what you just showed.
Having same issue with my 2019 street bob did u get it figured out?
Hey doc quick question. I have my cable disconnected and am adjusting internally via the derby cover. Can I adjust the clutch with the cable disconnected or am I wasting my time doing so?
Cable is disconnected because I’m waiting on parts. (Extension)
Sometimes it is difficult installing the cable after adjusting the clutch. It really depends on your dexterity and the slack in the cable with the adjuster at minimum….Doc
I appreciate the fast reply. I guess we’ll see if I’ll have to remove the derby cover again when my extension comes in.
My freeplay stays way too much after doing this on my 2018 Street Bob. Stock lever. Can that spring be too soft or what could be the reason? (My dealership doesn’t give a damn about it.)
the spring is supposed to set the "right" gap based in assuming the spring is putting the "right" pressure while is in the unlocked position right before you lock it for good at the final step.... but.... if it is failing you... i will say do yourself the spring function/ help the spring while in the unlocked position, and keep an eye on your gap at the handle, then proceed to lock it once you get the right gap... I am sure you will get it right after couple attempt.
Thats a great design they came out with, but as with all things plastic, its a failure point as it ages.