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techtalk:ref:priclutch02 [2019/11/14 04:16]
ixl2relax [Upgrade Clutch Diaphragm Springs - Pressure]
techtalk:ref:priclutch02 [2020/03/02 21:22] (current)
hippysmack [Clutch Pack]
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 \\ \\
  
 +====== Aftermarket Rivet Plate ======
 +
 +===== Alto Products =====
 +==== Spring Plate ====
 +
 +Alto Products Corp has developed a new version of the Harley Davidson spring separator plate (part# - 095763HD). ((thanks to rocketmangb for the tip)) \\
 +Made for Harley Davidson Sportster 91-On and Big Twin 90-On. \\
 +REF part number: (37975-90) can also be used in place of Alto # 095763. \\
 +This update features 16 Stainless Steel Rivets to hold the plate together for longer lasting durability, instead of the usual Brass Rivets. \\
 +This heavy duty replacement addresses the issue of the original brass rivets loosening over time. \\
 +
 +{{:​techtalk:​ref:​priclutch:​alto_ss_spring_plate.jpg?​direct&​300|}} ((Alto spring plate picture used by permission from Alto Products Corp.))
 +
 +
 +  * ..[[https://​www.altousa.com/​|Click here for the Alto website]]
 +  * ..[[https://​www.altousa.com/​docs/​catalogs/​Alto_Motorcycle_Catalog_19196.pdf|Click here to download their complete motorcycle catalog in PDF]].
 +
 +==== Clutch Pack ====
 +
 +Alto part numbers 095750BC and 095750CC are for Sportsters. \\
 +From Alto; \\
 +//This kit will correct, prevent, and reduce overheating of the Clutch Pack. \\
 +There is also an increased friction area for more grab and durability. \\
 +This kit uses our CARBONITE® material and is our strongest clutch in this application.//​ \\
 +
 +**Installation Instructions**:​ \\ [[https://​www.motorcycleid.com/​images/​alto/​items/​pdf/​095750nc-installation-instructions.pdf|Click here to download the instruction sheet PDF]]. ((Thanks to sml1226 for providing this link)) \\
 +The friction material should face the back of the drum. \\
 +  * Start with an externally splined friction plate with the lining facing down and the steel side facing up.
 +  * Followed by an internally splined friction plate with the lining facing down and the steel side up.
 +  * Continue this process making sure each time a plate is installed that you only see the steel side. 
 +  * The last plate to be installed will be the double-sided friction plate (in the front).
 +  * Reinstall the pressure plate and spring. Finish by adding lubricant.
 +  * Once installation is finished ride the motorcycle two or three times to make your final adjustments. \\ If the Stack Up extends above the basket, remove internally splined plate and one externally splined plate.
 +
 +
 +**ALTO Part #​(095750BC)**:​ \\
 +For Big Twin 90-97 & XLS 91+ \\
 +Contents: \\
 +  * (10) 095731B185 1-Side Friction, Internally Splined
 +  * (10) 095730D150 1-Side Friction, Externally Splined
 +  * (1) 095730A185 Friction Plate, Double Sided
 +
 +**ALTO Part # (095750CC)**:​ \\
 +Buell & XL 2005+ \\
 +Contents: \\
 +  * (8) 095731B185 1-Side Friction, Internally Splined
 +  * (8) 095730D150 1-Side Friction, Externally Splined
 +  * (1) 095730A185 Friction Plate, Double Sided
 +
 +==== Pics of ALTO (095750BC) Installed ​ ====
 +
 +Note that the plates are all fiber on one side and steel the other except the last one which is fiber on both sides. ((rocketmangb of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​t=2075976&​page=2)) \\
 +Installation is with the 2 sided plates in first and the 2 sided fiber in last (front). \\ 
 +
 +{{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_1_by_rocketmangb.jpg?​direct&​300|}} {{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_2_by_rocketmangb.jpg?​direct&​300|}} {{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_3_by_rocketmangb.jpg?​direct&​300|}} \\
 +
 +{{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_4_by_rocketmangb.jpg?​direct&​300|}} {{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_5_by_rocketmangb.jpg?​direct&​300|}} {{:​techtalk:​ref:​priclutch:​alto_carbonite_clutch_6_by_rocketmangb.jpg?​direct&​300|}} \\
 ====== 91 and Later Aftermarket Clutch Packs ====== ====== 91 and Later Aftermarket Clutch Packs ======
 ===== Energy One ===== ===== Energy One =====
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 This discussion regards using some of the clutch parts found in the XR1200 model in place of the stock XL model design. This XR parts usage was initially explored due to some issues that occur after the XL Spring Plate is replaced with an aftermarket 'Extra Plate Kit' or when adding 2 stock steels & a friction. Sometimes those alternatives will 1) have an abrupt grabbing (lurching) on clutch engagement and/or 2) produce an unpleasant squeel. Using the XR parts instead of the XL Spring Plate is said to eliminate those issues. This discussion regards using some of the clutch parts found in the XR1200 model in place of the stock XL model design. This XR parts usage was initially explored due to some issues that occur after the XL Spring Plate is replaced with an aftermarket 'Extra Plate Kit' or when adding 2 stock steels & a friction. Sometimes those alternatives will 1) have an abrupt grabbing (lurching) on clutch engagement and/or 2) produce an unpleasant squeel. Using the XR parts instead of the XL Spring Plate is said to eliminate those issues.
  
-The XLForum threads related to this alternative ​are (Thanks to Bluto for pioneering this alternative):​+These are the XLForum threads related to this alternative(Thanks to Bluto for pioneering this alternative):​
  
 http://​xlforum.net/​forums/​showthread.php?​t=2044017\\ http://​xlforum.net/​forums/​showthread.php?​t=2044017\\
 http://​xlforum.net/​forums/​showthread.php?​t=2072418\\ http://​xlforum.net/​forums/​showthread.php?​t=2072418\\
 +http://​xlforum.net/​forums/​showthread.php?​t=2074994\\
  
 Here's the pictures Bluto posted of the parts: Here's the pictures Bluto posted of the parts:
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 In both designs, the clutch pack is a combination of friction plates and steel plates that are sandwiched together between the base of the clutch hub and the pressure plate. In the stock XL design, there are 8 friction plates, 6 steel plates & one spring plate (see below). In both designs, the clutch pack is a combination of friction plates and steel plates that are sandwiched together between the base of the clutch hub and the pressure plate. In the stock XL design, there are 8 friction plates, 6 steel plates & one spring plate (see below).
  
-The XR1200 model was offered between 2008 & 2013. The clutch design in this model uses springs built into the clutch hub along with a bevelled spring plate (known as a Judder Plate) to absorb clutch engagement forces. The XL models also use a spring plate, but it consists of two metal plates that are connected with spring leafs that are riveted in place. This XL spring plate, especially in the rubbermount models, has failed quite often by the rivets sheering. Most often, the clutch basket is scarred. This requires careful filing to remove the raised areas on the damaged clutch basket so that the friction & steel plates can move back and forth smoothly. +The XR1200 model was offered between 2008 & 2013. The clutch design in this model uses springs built into the clutch hub along with a bevelled spring plate (known as a Judder Plate) to absorb clutch engagement forces. The XL models also use a spring plate, but it consists of two metal plates that are connected with spring leafs that are riveted in place. This XL spring plate, especially in the rubbermount models, has failed quite often by the rivets sheering. Most often, the clutch basket is scarred. This requires careful filing to remove the raised areas on the damaged clutch basket so that the friction & steel plates can move back and forth smoothly.\\
 {{ :​techtalk:​ref:​priclutch:​91-later-xl-alt-clutch.jpg?​500|}} {{ :​techtalk:​ref:​priclutch:​91-later-xl-alt-clutch.jpg?​500|}}
 +
 The XR1200 clutch basket is not a drop in replacement for the XL design but the Judder Plate portion of that design will fit into the stock XL basket. In this implementation,​ the XL spring plate, subject to many failures, is removed. In this XL alternative configuration,​ there is the Judder Plate plus 8 friction plates and 8 steel plates. The XR1200 clutch basket is not a drop in replacement for the XL design but the Judder Plate portion of that design will fit into the stock XL basket. In this implementation,​ the XL spring plate, subject to many failures, is removed. In this XL alternative configuration,​ there is the Judder Plate plus 8 friction plates and 8 steel plates.
  
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 As regards the bevelled spring, the inside diameter should sit closer to the Hub Base and the outside diameter should sit closer to the Pressure Plate. As regards the bevelled spring, the inside diameter should sit closer to the Hub Base and the outside diameter should sit closer to the Pressure Plate.
  
-(Note: This configuration is a new experiment - implement it as you see fit. Additional notes will be added as more experiences are related on the XLForum regarding the success.)+**NOTE-1:** With the Judder design, which requires additional motion in the clutch compression process, I would expect it to be more difficult to get the correct setting of the adjustment screw (perfectly balanced) to allow enough motion for the plates to get from fully engaged to fully disengaged. Pay close attention when you make the clutch adjustment of the ball & ramp assembly so that the clutch plates will move sufficiently. 
 + 
 + 
 +(**Note of Caution:** This configuration is a new experiment - implement it as you see fit. Additional notes will be added as more experiences are related on the XLForum regarding the success.) 
  
 **XR Parts to Replace Stock XL Spring Plate**\\ **XR Parts to Replace Stock XL Spring Plate**\\