Table 5-4. Clutch troubleshooting
SYMPTOM | CHECK ORDER | CAUSE | REMEDY |
Clutch slips | 1 | Incorrect clutch release adjustment | Check and adjust clutch release mechanism. |
2 | Worn clutch plates | Check service wear limits. Replace plates. | |
Clutch drags | 1 | Incorrect clutch release adjustment | Check and adjust clutch release mechanism. |
2 | Worn clutch release ramps or balls | Replace release ramps and/or balls. | |
3 | Warped clutch steel plates | Replace clutch steel plates. | |
4 | Worn or damaged clutch gear splines | Replace clutch gear or hub as required. | |
5 | Overfilled primary | Drain lubricant to correct level. |
Removal
PART NUMBER | TOOL NAME |
HD-38362 | SPORTSTER 5-SPEED SPROCKET LOCKING LINK |
HD-46283 | PRIMARY DRIVE LOCKING TOOL |
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding.
Note. See Figure 5-10. If replacement of clutch pack (28) is the only service work required, perform REMOVAL steps 1 and 4 only, and then proceed to the NOTES under DISASSEMBLY.
Figure 5-10. Clutch assembly: XL models: 1. Retaining ring; 2. Clutch shell and sprocket; 3. Ball bearing; 4. Retaining ring; 5. Clutch hub; 6. Spring washer; 7. Mainshaft nut; 8. Spring plate; 9. Steel plate (6); 10. Friction plate, fiber (8); 11. Pressure plate; 12. Adjusting screw; 13. Bearing; 14. Retaining ring; 15. Release plate; 16. Retaining ring; 17. Diaphragm spring; 18. Spring seat; 19. Retaining ring; 20. Retaining ring; 21. Inner ramp; 22. Outer ramp; 23. Nut; 24. Locking plate; 25. Clutch adjustment spring; 26. Ball (3); 27. Clutch cable coupling; 28. Clutch pack (consists of items 8, 9,10)
1. Disconnect negative (-) battery cable from stud on engine crankcase behind starter motor assembly. See 1.22 BATTERY MAINTENANCE.
2. Open left side cover. See 2.18 LEFTSIDE COVER.
3. Remove positive (+) battery cable from battery positive (+) terminal. See 1.22 BATTERY MAINTENANCE.
4. Remove the primary cover. Discard the primary cover gasket. See 5.3 PRIMARY COVER.
Note. See Figure 5-9. Do not position the sprocket locking link too close to the shifter shaft (2). If the sprocket locking link contacts the shifter shaft the sprocket locking link may damage the shifter shaft and/or the engine crankcase.
Figure 5-9. Using sprocket locking link (part No. HD-46283 or HD-38362) to loosen engine sprocket nut: 1. Sprocket locking link; 2. Shifter shaft
5. Install a locking link:
- a. XL 883 Models: Use SPORTSTER 5-SPEED SPROCKET LOCKING LINK (Part No. HD-38362).
- b. XL 1200 Models: Use PRIMARY DRIVE LOCKING TOOL (Part No. HD-46283).
6. Remove the engine sprocket nut. Do not remove engine sprocket at this time.
7. See Figure 5-10. Remove large retaining ring (16). Remove adjusting screw assembly (12, 13, 14 and 15) from pressure plate (11).
Note. Transmission mainshaft nut (7) has left-hand threads. Turn nut clockwise to loosen and remove from mainshaft.
8. Remove mainshaft nut (7) and spring washer (6).
9. Remove the clutch assembly, primary chain and engine sprocket as an assembly from the vehicle.
10. Inspect primary chain. Replace if necessary.
11. Inspect stator and rotor. Replace if necessary. See 6.24 ALTERNATOR.
Disassembly
PART NUMBER | TOOL NAME |
HD-38515-91 | CLUTCH SPRING FORCING SCREW |
HD-38515-A | SPRING COMPRESSING TOOL |
Notes:
- See Figure 5-10. If replacement of clutch pack (28) is the only service work required, perform DISASSEMBLY Steps 2-5 and 7 only, and then proceed to the NOTE under INSPECTION AND REPAIR.
- Observe all WARNING and CAUTION statements which apply to the steps specified.
1. See Figure 5-10. With clutch assembly removed from primary chaincase, install the adjusting screw assembly (12, 13, 14 and 15) into the pressure plate (11):
- a. Match the two tabs on release plate (15) to the notches in the pressure plate.
- b. Install the retaining ring (16).
Warning! Disassemble clutch using a spring compressing tool. The diaphragm spring is compressed and, if removed without proper tools can fly out, which could result in death or serious injury.
2. See Figure 5-11. Compress clutch diagram spring.
- a. Thread the CLUTCH SPRING FORCING SCREW (Part No. HD-38515-91) onto the clutch adjusting screw.
- b. Place the bridge of the SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring.
- c. Thread the tool handle onto end of forcing screw.
Figure 5-11. Compressing clutch diaphragm spring: 1. Forcing screw; 2. Bridge, spring compressing tool; 3. Handle; 4. Open-end wrench
Note. See Figure 5-10. Turn compressing tool handle only enough to remove retaining ring (19) and spring seat (18). Excessive compression of diaphragm spring could damage clutch pressure plate.
3. See Figure 5-10. With a wrench on the clutch spring forcing screw flats to prevent the forcing screw from turning, turn handle clockwise until tool relieves pressure on retaining ring (19) and spring seat (18).
4. Remove and discard retaining ring. Remove spring seat from the groove in clutch hub (5) prongs. Remove the assembly of diaphragm spring (17), pressure plate (11), adjusting screw components (12, 13, 14 and 15) and compressing tool.
5. Turn the compressing tool handle counterclockwise until the clutch spring forcing screw disconnects from the clutch adjusting screw. Remove spring seat and diaphragm spring from pressure plate assembly.
6. Remove retaining ring (16) and adjusting screw assembly from pressure plate. If necessary, disassemble adjusting screw assembly by removing retaining ring (14), and then separating the remaining adjusting screw components (12, 13, and 15).
7. Remove the clutch pack (28) from the clutch hub. The clutch pack consists of one spring plate (8), six steel plates (9), and eight friction (fiber) plates (10).
Note. See Figure 5-10. Bearing (3) will be damaged by disassembly of clutch hub (5) and shell (2). Always replace bearing (3) if hub and shell are disassembled. If the assembly is pressed apart, the bearing must be replaced.
8. If necessary, disassemble clutch shell and clutch hub as follows:
- a. Remove retaining ring (1) from inboard end of clutch hub (5).
- b. Using an arbor press, separate clutch hub from assembly of clutch shell (2), bearing (3), and retaining ring (4).
- c. Remove retaining ring (4) from groove in clutch shell.
- d. Press on the inboard side of bearing (3) outer race to remove bearing from clutch shell.
Inspection and repair: XL models
Note. See Figure 5-10. If replacement of clutch pack (28) is the only service work required, perform all INSPECTION AND REPAIR steps (except Step 2f), and then proceed to the NOTES under ASSEMBLY.
Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
1. See Figure 5-10. Wash all parts, except the friction plates (10) and bearings (3 and 13), in a non-volatile cleaning solution or solvent. Blow parts dry with low pressure compressed air.
2. Examine the clutch components as follows:
- a. Inspect all clutch plates for wear and discoloration.
- b. Inspect all friction plates (10) for worn lining surfaces or checked or chipped linings.
- c. Inspect each steel plate (9) for grooves.
- d. Place each steel plate on a flat surface. Using a feeler gauge, check for flatness in several places. If any one ofthe plates are damaged, or warped more than 0.006 in (0.15 mm), replace the entire clutch pack.
- e. Wipe the lubricant from the seven wide friction plates.
- f. See Figure 5-12. Measure the thickness of each friction plate. If any one ofthe plates is less than 0.0795 in (2.02 mm), replace the entire clutch pack.
- g. See Figure 5-10. Inspect clutch shell ball bearing (3) for smoothness by rotating clutch shell while holding clutch hub. If bearing is rough or binds, it must be replaced.
- h. See Figure 5-13. Check the primary chain sprocket (3) and the starter ring gear (4) on the clutch shell (1). If either sprocket or ring gear are badly worn or damaged, replace the clutch shell.
- i. Check the slots (5, 6) that mate with the clutch plates on both clutch shell and clutch hub (2). If slots are worn or damaged, replace shell and/or hub.
- j. See Figure 5-10. Check the diaphragm spring (17) for cracks or bent tabs. Install a new spring if either condition exists.
Figure 5-12. Friction plate thickness
Figure 5-13. Checking clutch hub and clutch shell: 1. Clutch shell; 2. Clutch hub; 3. Primary chain sprocket; 4. Starter ring gear; 5. Clutch hub slots; 6. Clutch shell slots
Assembly
PART NUMBER | TOOL NAME |
HD-38515-91 | CLUTCH SPRING FORCING SCREW |
HD-38515-A | SPRING COMPRESSING TOOL |
Notes:
- See Figure 5-10. If replacement of clutch pack (28) is the only service work required, perform all ASSEMBLY Steps except 2, 5 and 6, and then proceed to the NOTE under INSTALLATION.
- Replace the clutch pack, steel plates, friction plates and spring plate, as a set.
1. Submerge and soak all friction and steel plates in GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT for at least five minutes.
2. See Figure 5-14. Assemble the clutch hub (1) and clutch shell (4):
- a. Press a new ball bearing (3) into clutch shell.
- b. Secure the bearing with a new retaining ring (2).
- c. Press inboard end of clutch hub into clutch shell bearing.
- d. Secure with a new retaining ring (5) on end of hub.
Figure 5-14. Clutch hub and shell assembly: 1. Clutch hub; 2. Retaining ring; 3. Ball bearing; 4. Clutch shell; 5. Retaining ring
Note. See Figure 5-10. The clutch pack (28) consists of one spring plate (8), six steel plates (9) and eight friction (fiber) plates (10).
3. Install clutch pack into clutch shell in order:
F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F
(F = Friction plate, St = Steel plate, Sp = Spring plate)
4. Place pressure plate (11) and adjusting screw onto clutch pack (28).
5. Assemble bearing (13) and adjusting screw (12) in release plate (15). Secure with new retaining ring (14).
6. Align the two tabs on perimeter of release plate (15) with the corresponding recesses in pressure plate. Install adjusting screw assembly (12, 13, 14, 15) into pressure plate (11). Secure adjusting screw assembly with new retaining ring (16).
7. Install diaphragm spring (17) with its concave side facing inboard (toward pressure plate), onto pressure plate assembly. Align square openings of pressure plate and diaphragm spring (17).
8. Position spring seat (18) with its flat, larger outer diameter side facing inboard (toward diaphragm spring).
9. Install a new retaining ring (19) onto convex (outboard) side of diaphragm spring.
10. Thread the CLUTCH SPRING FORCING SCREW (Part No. HD-38515-91) onto the clutch adjusting screw. Place the bridge of the SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring. Thread the tool handle onto end of forcing screw. Do not tighten compressing tool against diaphragm spring at this time.
11. See Figure 5-11. Place an open-end wrench (4) on the clutch spring forcing screw (1) flats to prevent the forcing screw from turning.
Note. Turn compressing tool handle only enough to install spring seat and retaining ring. Excessive compression of diaphragm spring could damage clutch pressure plate.
12. See Figure 5-10. Turn compressing tool handle clockwise to compress diaphragm spring (17). Compresses just enough to install spring seat (18) and retaining ring (19) into the groove in clutch hub (5) prongs.
13. Verify retaining ring is positioned against flange face (outboard side) of spring seat and fully seated in groove of clutch hub. Carefully loosen and remove compressing tool.
Note. As the compressing tool is removed, the diaphragm spring will move outward. This movement will force the spring seat up into the inside of the retaining ring. The spring seat provides an operating surface for the diaphragm spring. Additionally, it prevents the retaining ring from coming out during operation.
Installation
PART NUMBER | TOOL NAME |
HD-38362 | SPORTSTER 5-SPEED SPROCKET LOCKING LINK |
HD-46283 | PRIMARY DRIVE LOCKING TOOL |
FASTENER | TORQUE VALUE | |
Engine sprocket nut: XL Models | 240-260 ft·lbs | 326-353 Nm |
Transmission mainshaft nut: XL Models | 50-60 ft·lbs | 67.8-81.3 Nm |
Note. See Figure 5-10. If replacement of clutch pack (28) is the only service work required, perform INSTALLATION last step only.
1. See Figure 5-10. Remove retaining ring (16). Remove adjusting screw assembly (12, 13, 14, 15) from pressure plate (11). This allows installation of the transmission mainshaft nut and washer.
2. Clean the oil off the threads of the engine sprocket shaft, the engine sprocket nut, the transmission mainshaft and the mainshaft nut.
3. Install the engine sprocket, primary chain and clutch assembly as a unit.
Note. See Figure 5-15. Do not position the sprocket locking link too close to the shifter shaft (2). If the sprocket locking link contacts the shifter shaft while tightening the engine sprocket nut, the shifter shaft and/or the engine crankcase may be damaged.
Figure 5-15. Tighten engine sprocket fastener (typical): 1. Sprocket locking link; 2. Shifter shaft
4. See Figure 5-15. Install the sprocket locking link.
- a. XL 883 Models: Use the SPORTSTER 5-SPEED SPROCKET LOCKING LINK (Part No. HD-38362).
- b. XL 1200 Models: Use the PRIMARY DRIVE LOCKING TOOL (Part No. HD-46283).
5. Apply two or three drops of LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) onto threads of engine sprocket shaft.
6. Install engine sprocket nut. Tighten to 240-260 ft·lbs (326-353 Nm).
Note. See Figure 5-16. Washer (2) must be installed with the word "out" facing the transmission mainshaft nut (1). Incorrect assembly can result in clutch and/or transmission failure.
Figure 5-16. Mainshaft nut and washer: 1. Mainshaft nut; 2. Spring washer; 3. Clutch hub
7. See Figure 5-16. Apply two or three drops of LOCTITE 262 HIGH STRENGTH THREADLOCKERAND SEALANT (red) onto threads of transmission mainshaft. Install spring washer (2) and mainshaft nut (1) (left-hand threads) on transmission mainshaft. Tighten nut to 50-60 ft·lbs (67.881.3 Nm).
8. Remove the sprocket locking link.
9. See Figure 5-17. Install adjusting screw assembly (1) in pressure plate, noting that two tabs on perimeter of release plate must be inserted into corresponding recesses in pressure plate. Secure assembly with a new retaining ring (2).
Figure 5-17. Clutch adjusting screw assembly and retaining ring: 1. Adjusting screw assembly; 2. Retaining ring
10. Install primary cover using new gasket. See 5.3 PRIMARY COVER.
11. Adjust primary chain and clutch. See 1.9 PRIMARY CHAIN and 1.11 CLUTCH.
12. Fill transmission with GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT See 1.10 TRANSMISSION LUBRICANT.
13. Connect battery and close left side cover. See 1.22 BATTERY MAINTENANCE.