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techtalk:evo:priclutch01 [2019/07/10 15:08]
hippysmack [Clutch Release Adjustment - Why & How]
techtalk:evo:priclutch01 [2019/11/14 02:58] (current)
ixl2relax [Aftermarket & Upgrade Clutch Parts]
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 On the other hand, for 1991-1993 models, which also have five-speed transmissions,​ while the clutch operation is the same, the Ball & Ramp Assembly is mounted to the inside of the Primary Cover (as illustrated for 1984L-1990 four-speed models). This necessitates the removal of the Primary Cover in order to replace either the B&R unit or the Adjuster Bearing unit on those models. On the other hand, for 1991-1993 models, which also have five-speed transmissions,​ while the clutch operation is the same, the Ball & Ramp Assembly is mounted to the inside of the Primary Cover (as illustrated for 1984L-1990 four-speed models). This necessitates the removal of the Primary Cover in order to replace either the B&R unit or the Adjuster Bearing unit on those models.
- 
  
 \\ \\
 +
  
 ===== Removing the Clutch Pack - 5-Speed ===== ===== Removing the Clutch Pack - 5-Speed =====
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 Remove the Clutch Inspection Cover (off the Primary Housing - Small Cover on '​86-'​93 - Large 'Derby Cover' on '​94-up) (You may have to loosen or remove the left mid-mount foot peg) - be careful as you remove the cover because there is an internal spring & Release Adjuster Position Lock Nut - Remove the internal spring & Release Adjuster Position Lock Nut… Remove the Clutch Inspection Cover (off the Primary Housing - Small Cover on '​86-'​93 - Large 'Derby Cover' on '​94-up) (You may have to loosen or remove the left mid-mount foot peg) - be careful as you remove the cover because there is an internal spring & Release Adjuster Position Lock Nut - Remove the internal spring & Release Adjuster Position Lock Nut…
  
-Turn the center screw of the Release Adjuster clockwise one turn away from the original position to be sure you are fully unloading any pressure - then **slowly turn the Release Adjuster screw COUNTERCLOCKWISE until you feel ANY CHANGE IN TENSION** ​ - Do this a few times to be sure you feel the right spot where tension begins – When you're satisfied you have the right spot, turn the adjuster screw back __clockwise 1/4 to 3/8 of a turn__ ​ to be sure no preload tension is on the Diaphragm Spring.+Turn the center screw of the Release Adjuster clockwise one turn away from the original position to be sure you are fully unloading any pressure - then **slowly turn the Release Adjuster screw COUNTERCLOCKWISE until you feel ANY CHANGE IN TENSION** ​ - Do this a few times to be sure you feel the right spot where tension begins – When you're satisfied you have the right spot, turn the adjuster screw back __clockwise 1/4 to 3/8 of a turn__ ​ to be sure no preload tension is on the Diaphragm Spring. ​ 
  
 **Side note**: \\ **Side note**: \\
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 **BE EXTREMELY CAREFUL WHEN OPERATING THE BIKE AFTER MAKING A CLUTCH ADJUSTMENT - IF YOU GOT IT WRONG, THE BIKE MAY SURGE FORWARD WHEN YOU PUT IT IN GEAR EVEN THOUGH YOU HAVE THE CLUTCH LEVER PULLED FULLY AGAINST THE GRIP!!! BE SAFE - CHECK & DOUBLE CHECK!!!** **BE EXTREMELY CAREFUL WHEN OPERATING THE BIKE AFTER MAKING A CLUTCH ADJUSTMENT - IF YOU GOT IT WRONG, THE BIKE MAY SURGE FORWARD WHEN YOU PUT IT IN GEAR EVEN THOUGH YOU HAVE THE CLUTCH LEVER PULLED FULLY AGAINST THE GRIP!!! BE SAFE - CHECK & DOUBLE CHECK!!!**
 +
 +==== Pics ====
 +\\
 +=== Adjusting the clutch cable on a 98 model ===
 +
 +{{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_1_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_2_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_3_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) \\
 +
 +{{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_4_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_5_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{:​techtalk:​evo:​priclutch:​adjusting_-_removing_clutch_cable_6_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) \\
 +
 +=== Adjusting clutch ramp assembly on a 98 model ===
 +
 +{{:​techtalk:​evo:​priclutch:​adjusting_clutch_1_by_hippysmack.jpg?​direct&​300|}} {{:​techtalk:​evo:​priclutch:​adjusting_clutch_2_by_hippysmack.jpg?​direct&​300|}} \\
 +
 +{{:​techtalk:​evo:​priclutch:​adjusting_clutch_3_by_hippysmack.jpg?​direct&​300|}} {{:​techtalk:​evo:​priclutch:​adjusting_clutch_4_by_hippysmack.jpg?​direct&​300|}} {{:​techtalk:​evo:​priclutch:​adjusting_clutch_5_by_hippysmack.jpg?​direct&​300|}} \\
  
 \\ \\
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 NOTE: The stock Bearing(B) and Release Plate(C) can be purchased already assembled. Part number 36731-91 is the release plate assembly, which includes both the 37918-91 release plate and the stock 8885 bearing. NOTE: The stock Bearing(B) and Release Plate(C) can be purchased already assembled. Part number 36731-91 is the release plate assembly, which includes both the 37918-91 release plate and the stock 8885 bearing.
  
-\\+==== Pics ==== 
 +Adjusting the clutch release on a 98 model. \\ 
 +{{:​techtalk:​evo:​priclutch:​removing_clutch_adjustment-bearing_assembly_2_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) ​\\
  
-==== Upgrade Clutch Release Bearing - HD P/N 8885 to 7200B Angular Ball Bearing ====+{{:​techtalk:​evo:​priclutch:​removing_clutch_ramp_assembly_1_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)){{:​techtalk:​evo:​priclutch:​removing_clutch_ramp_assembly_2_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)){{:​techtalk:​evo:​priclutch:​removing_clutch_ramp_assembly_3_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) \\
  
-You might consider replacing the stock bearing, P/N 8885, which is a standard ball type bearing (equivto 6200). Using an angular contact bearing, which provides additional support in the axial direction, is a better alternative for this application. The upgraded replacement would be 7200B (not supplied ​by HDand is an angular contact bearing. Thus, it is important to orient the bearing in the right direction when pressing the bearing into the Release Plate.+{{:​techtalk:​evo:​priclutch:​removing_clutch_ramp_assembly_4_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) {{:​techtalk:​evo:​priclutch:​removing_clutch_ramp_assembly_5_by_hippysmack.jpg?​direct&​300|}} ​((photo ​by Hippysmack)) {{:​techtalk:​evo:​priclutch:​removing_clutch_adjustment-bearing_assembly_1_by_hippysmack.jpg?​direct&​300|}} ((photo by Hippysmack)) \\
  
-The wide side of the 7200B outer bearing race should be placed into the release plate first. This also means that the narrow part of the inner bearing race is first into the plate.+\\
  
-When correctly assembled, the narrow part of the outer race and the wide part of the inner race will each be exposed on the insertion side of the release plate. The Adjustment Screw is inserted into that wide side of the inner race, as shown below.+==== Upgrade Clutch Release Bearing - HD P/N 8885 to 7200B Angular Ball Bearing ====
  
-{{:​techtalk:​evo:​priclutch:​clutchreleasebearing-compare8885-7200b.jpg?​400|}} ​ {{:​techtalk:​evo:​priclutch:​clutchreleasebearing-destroyed8885.jpg?400|}}((Pics by goblin_dust at this thread: http://​xlforum.net/​forums/​showthread.php?​t=1987885 - Annotated by IXL2Relax at the XLForum))+You might consider replacing the stock bearing, P/N 8885, which is a standard ball type bearing (equivto 6200)Using an angular contact bearing ​(FAG 7200B), which provides additional support in the axial direction, is a better alternative for this application.
  
-{{:​techtalk:​evo:​priclutch:​clutchreleasebearing-7200b-angular.jpg?400|}}((Thanks to Reddtigger - xlforum.net/​forums/​showthread.php?​t=1688139)) ​ ​{{:​techtalk:​evo:​priclutch:​clutchreleasebearing-7200b-angular-bolt.jpg?​400|}}((Annotated by IXL2Relax at the XLForum))+When the original style bearing is worn out or damaged, it is a good time to consider an upgrade.\\ 
 +{{:​techtalk:​evo:​priclutch:​clutchreleasebearing-compare8885-7200b.jpg?​400|}} ​ {{:​techtalk:​evo:​priclutch:​clutchreleasebearing-destroyed8885.jpg?​400|}}((Pics by goblin_dust at this thread: http://​xlforum.net/​forums/​showthread.php?​t=1987885 - Annotated by IXL2Relax at the XLForum))
  
-Additional discussion: +For more information,​ click this link to see the [[techtalk:ref:priclutch02#​upgrade_clutch_release_bearing_-_hd_p_n_8885_to_7200b_angular_ball_bearing|Clutch Parts & Mods - Aftermarket]] page in the REFerence section.
-http://xlforum.net/​forums/​showthread.php?​t=1688139+
  
 \\ \\
  
  
-====== Clutch Basket ======+====== Clutch Basket ​Parts ======
 **1986-1990 Clutch Basket Parts** - Used on All Models ((86-90 HD Sportster Parts Catalogs)) \\ **1986-1990 Clutch Basket Parts** - Used on All Models ((86-90 HD Sportster Parts Catalogs)) \\
   * 36791-84 - Clutch Shell and Sprocket   * 36791-84 - Clutch Shell and Sprocket
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   * 37495-91 - Main Shaft Nut \\   * 37495-91 - Main Shaft Nut \\
  
-====== ​Stock Diaphragm Springs & Clutch ​Plates ​======+====== Diaphragm Springs & Clutch ​Plate Parts ======
 **1986-1990 Diaphragm Spring** **1986-1990 Diaphragm Spring**
   * 36792-84 - Stock Diaphragm Spring used on All Models   * 36792-84 - Stock Diaphragm Spring used on All Models
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   * 37924-04 - Stock Diaphragm Spring used on E04 and 05 1200 Models ((2004 HD Sportster FSM 99451-04 pg 39)) ((2005 HD Sportster FSM 99451-05A pg 41))   * 37924-04 - Stock Diaphragm Spring used on E04 and 05 1200 Models ((2004 HD Sportster FSM 99451-04 pg 39)) ((2005 HD Sportster FSM 99451-05A pg 41))
   * 37924-04A (purple) - Stock Diaphragm Spring used on L04 and 06-up 1200 Models ((2004 HD Sportster FSM 99451-04A pg 41)) ((2006 HD Sportster FSM 99451-06 pg 41))   * 37924-04A (purple) - Stock Diaphragm Spring used on L04 and 06-up 1200 Models ((2004 HD Sportster FSM 99451-04A pg 41)) ((2006 HD Sportster FSM 99451-06 pg 41))
-    * HD Stock 1200 (2004-later) Diaphragm Spring Pressure is approx. 320lbs of pressure ((http://​www.phaedrus.me/​id155.html)) 
   * 37934-06 - Stock Diaphragm Spring used on XR-1200 / XR1200X Models ((2009 HD Sportster FSM 99451-09A pg 59))   * 37934-06 - Stock Diaphragm Spring used on XR-1200 / XR1200X Models ((2009 HD Sportster FSM 99451-09A pg 59))
 +    * HD Stock XR1200 Diaphragm Spring Pressure is approx. 320lbs of pressure ((http://​www.phaedrus.me/​id155.html))
  
 **1986-1990 Clutch Plates** - Used on All Models **1986-1990 Clutch Plates** - Used on All Models
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   * 36786-84 - 1ea - Stock Pressure Plate   * 36786-84 - 1ea - Stock Pressure Plate
  
-**1991-later Clutch Plates** - Used on All Models (except ​XR-1200 / XR1200X)+**1991-later Clutch Plates** - Used on All Models (slightly different on XR-1200 / XR1200X)
   * 37911-90 - 8ea - Stock Friction Plates (paper material)   * 37911-90 - 8ea - Stock Friction Plates (paper material)
   * 37913-90 - 6ea - Stock Steel Spacer Plates \\    * 37913-90 - 6ea - Stock Steel Spacer Plates \\ 
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 **2008 and later XR Clutch Plates** - Used on XR-1200 / XR1200X Models \\  **2008 and later XR Clutch Plates** - Used on XR-1200 / XR1200X Models \\ 
  
-  * 37897-02 - 1ea - Stock Friction Plate (narrow) 
   * 37911-90 - 7ea - Stock Friction Plates (paper material)   * 37911-90 - 7ea - Stock Friction Plates (paper material)
   * 37913-90 - 7ea - Stock Steel Spacer Plates \\    * 37913-90 - 7ea - Stock Steel Spacer Plates \\ 
-  * 37895-02 - 1ea - Stock Spring Seat Damper +  ​* 37897-02 - 1ea - Stock Judder Friction Plate (narrow) 
-  * 37894-02 - 1ea - Stock Rear Clutch ​Spring+  ​* 37895-02 - 1ea - Stock Judder ​Spring Seat 
 +  * 37894-02 - 1ea - Stock Judder ​Spring ​(beveled)
   * 37896-02 - 1ea - Stock Pressure Plate   * 37896-02 - 1ea - Stock Pressure Plate
 +
 +\\
  
 |  91-up clutch plates and spacing (F-St-F-St-F-St-F-SP-F-St-F-St-F-St-F). ((photos by Hippysmack)) ​ || |  91-up clutch plates and spacing (F-St-F-St-F-St-F-SP-F-St-F-St-F-St-F). ((photos by Hippysmack)) ​ ||
 |{{:​techtalk:​evo:​priclutch:​91-up_clutch_pack_spacing_2_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​priclutch:​91-up_clutch_pack_spacing_1_by_hippysmack.jpg?​direct&​300|}}| |{{:​techtalk:​evo:​priclutch:​91-up_clutch_pack_spacing_2_by_hippysmack.jpg?​direct&​300|}}|{{:​techtalk:​evo:​priclutch:​91-up_clutch_pack_spacing_1_by_hippysmack.jpg?​direct&​300|}}|
- 
-===== Upgrade Clutch Diaphragm Springs - Pressure ===== 
- 
-**L1984-90 Sportster** 
- 
-Barnett Scorpion Clutch Kit 607-30-10084 (( http://​www.barnettclutches.com/​media/​service_center/​607-30-10084.pdf)) 
-  * MT-33-6 - - - 396lbs (six springs) 
-  * MT-112-6 - - 420lbs (six springs) 
-  * MT-113-6 - - 480lbs (six springs) 
- 
-**1991-later Sportsters** 
- 
-Screamin’ Eagle HD-style Clutch Spring (( http://​www.phaedrus.me/​id155.html)) 
-  * 350lbs - 10% Stronger Than Stock 1200 Clutch Spring (SE Clutch Spring 37949-98A) 
- 
-Energy One HD-style Clutch Spring ((https://​www.energyoneclutches.com)) 
-  * ???lbs - 15% Stronger Than Stock 1200 Clutch Spring (BT15) 
-  * ???lbs - 25% Stronger Than Stock 1200 Clutch Spring (BT25) 
- 
-Barnett HD-style Clutch Spring ((http://​www.barnettclutches.com/​1845/​harley-davidson/​0/​0/​0-harley-davidson-1991-and%20later.html)) 
-  * 360lbs MT-81 - 10% Stronger Than Stock 1200 Clutch Spring (502-00-01081) 
-  * 400lbs MT-77 - 25% Stronger Than Stock 1200 Clutch Spring (502-00-01077) 
- 
-Barnett Scorpion Clutch Kit 607-30-10091 ((http://​www.barnettclutches.com/​media/​service_center/​607-30-10091.pdf)) 
-  * MT-18-6 - - - 348lbs (six springs) 
-  * MT-112-6 - - 420lbs (six springs) 
-  * MT-113-6 - - 480lbs (six springs) 
-These springs can be mixed such as: ((AB,Frank http://​xlforum.net/​forums/​showthread.php?​t=1799188)) 
-  * 3x MT-18 plus 3x MT-112 = 384 lbs 
-  * 3x MT-18 plus 3x MT-113 = 414 lbs 
-  * 3x MT-112 plus 3x MT-113 = 450 lbs 
  
 \\ \\
  
-===== Screamin' ​Eagle® Performance Clutch Kit =====+"​Beginning in 2004, the 883 models started coming with a lighter clutch spring than the 1200's."​((aswracing from http://​xlforum.net/​forums/​showthread.php?​t=1953378))\\ 
 +This was to reduce the effort required to pull the clutch lever. There was also a change in the\\ clutch cable in 2007 to help reduce the clutch lever effort.
  
-HD has a Performance Clutch Kit (Number 38002-04) designed to fit 1991 and later XL and 1994 to 1997 1340 Evolution® model motorcycles.(( shanneba from the XLFORUM)) ​  This kit is still being sold by HD as of 12-22-2016. +|  Notice the difference in the slots between the Diaphragm Spring fingers of '91-'03 and '04-later springs.\\ On the left is an '01 example ​and on the right is an '06 exampleBoth are 883 model springs.((http://xlforum.net/​forums/​showpost.php?​p=4923807&​postcount=7 ​Graywolf))((http:​//xlforum.net/forums/showthread.php?​t=49915 - CJBurr))  || 
- + {{:​techtalk:​evo:​priclutch:clutch-assy-01-883-stock-graywolf.jpg?​300|}} ​ |  {{:techtalk:​evo:​priclutch:clutch-assy-06-883-stock-cjburr.jpg?​300|}} ​ |
-  * The nine high performance friction discs and eight spacer discs in this kit replace ​the original eight paper friction discs and six spacer discsThis kit also replaces the spring plate and diaphragm spring with a higher rate diaphragm spring.(( https://serviceinfo.harley-davidson.com/sip/service/document/2295)) +
-  ​* CautionsDo not reinstall the OE spring plate and diaphragm spring with this kit. Doing so will affect the stacked height of the clutch ​discsThe spacer discs supplied in this kit must be used with the high performance friction discs. Do not use the original equipment (OE) spacer discs with this kit. Doing so will affect the stacked height of the clutch discs, resulting in clutch slippage. +
-  * Installation,​ refer to the applicable Harley-Davidson Service Manual for installation of friction discs, spacer discs, and diaphragm spring in kit, but follow these important guidelines: +
-      * Remove the original eight friction discs, six spacer discs, spring plate, and diaphragm spring from the clutch assembly as described in the Service Manual, and discard. +
-      * Replace with nine high performance friction discs, eight spacer discs, and diaphragm spring from kit. Place a friction disc into the clutch shell first, then alternate spacer discs and friction discs. +
-      * Kit includes: +
-        * Disc set including 9 friction and 8 spacer discs. Part #​(38001-04) +
-        * 1 Spring, ​clutch ​diaphragm Part #(37949-98A) +
-\\ +
-\\+
  
 ====== Spring Plate Failure ====== ====== Spring Plate Failure ======
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-You may also want to explore this page in the REFerence section: +**NOTE:** Alto has released an upgraded Spring Plate design for the '​91-later Sportsters - Alto P/N 095763HD. It utilizes Stainless Steel rivets instead of the previous Brass Rivets design. Time will tell if this is more reliable.((Rocketmangb at http://​xlforum.net/​forums/​showthread.php?​t=2074441)) ​[[https://​www.altousa.com/​images/​new_products/​Alto__095763HD_Harley_Davidson_Spring_Plate_with_NEW_Stainless_Rivets.pdf|>>>​Link To Alto PDF<<<​]]
-[[techtalk:ref:​priclutch02|'​91-later Alternative Clutch Pack Using XR1200 Parts]]+
  
 +\\
 +\\
  
 +====== Clutch Parts & Mods - Aftermarket ======
 +
 +<font 20px/Arial, , ;;#​00ffff;;#​000000>​To explore more options in the REFerence section, click the link below:</​font>​
 \\ \\
-[[:techtalk:menu|{{:​techtalk:​gototechnicalmenu.jpg?​nolink&}}]]+<font 20px/​Arial>​ 
 +\\ 
 +[[techtalk:ref:​priclutch02|Clutch Parts Mods - Aftermarket]]\\ 
 +</​font>​
  
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 +\\
 +\\
 +[[:​techtalk:​menu|{{:​techtalk:​gototechnicalmenu.jpg?​nolink&​}}]]
  
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