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REF: Primary Drive & Clutch

91 and Later Aftermarket Clutch Packs

Energy One

BTX-11:
9 Kevlar friction plates, 8 steel plates plus a 15% stronger diaphragm spring. ¹⁾
Recommended fluid type:
The use of synthetics is not recommended as they tend to cause slippage. ²⁾

Any HD petroleum based, non-synthetic, primary oil, as light weight as possible.
Or even a good petroleum based motor oil such as 10/40 or 20/50 in weight.
You can even use ATF Type F or B&M Trickshift.

Installation:
Start with a friction plate and end with a friction plate. ³⁾
The OEM rivet plate is discarded and not used with this kit.
This kit includes 1 extra friction and steel plate to retain the OEM stack height.

Energy One BTX-11 ⁴⁾	Soaking the plates in oil ⁵⁾

Screamin' Eagle® Performance Clutch Kit

HD has a Performance Clutch Kit (Number 38002-04) designed to fit 1991 and later XL and 1994 to 1997 1340 Evolution® model motorcycles.⁶⁾ This kit is still being sold by HD as of 12-22-2016.

The nine high performance friction discs and eight spacer discs in this kit replace the original eight paper friction discs and six spacer discs. This kit also replaces the spring plate and diaphragm spring with a higher rate diaphragm spring.⁷⁾
Cautions: Do not reinstall the OE spring plate and diaphragm spring with this kit. Doing so will affect the stacked height of the clutch discs. The 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)

Barnett Kevlar Clutch Kit

In this section, Grind, from the XLForum.net, notes that he had ordered a new Barnett Kevlar clutch pack & Barnett 25% stronger diaphragm spring for his 2004 1200C Sportster. The pictures below are from that thread: ⁸⁾

These are the instructions that came with the kit:

This Barnett Kit still came with the Judder Plate (which Barnett no longer uses):

Here is a comparison of the Stock Diaphragm Spring & the Barnett 25% upgrade spring:

Lastly, here is a comparison of four brands of Friction Plates.
Top to Bottom is: Stock HD, Energy One Kevlar, Alto Carbonite & Barnett Kevlar:

Upgrade Clutch Diaphragm Springs - Pressure

Below are a list of upgrade versions. The 'xx% stronger' are claimed values by the respective vendors. Energy One suggests that if you are using a diaphragm spring of +25% that you should also upgrade your pressure plate to a billet version because they have had issues with the stock cast pressure plate cracking. ⁹⁾

L1984-90 Sportster

Barnett Scorpion Clutch Kit 607-30-10084 ¹⁰⁾

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 ¹¹⁾

350lbs - 10% Stronger Than Stock 1200 Clutch Spring (SE Clutch Spring 37949-98A)

Energy One HD-style Clutch Spring ¹²⁾

340lbs - 15% Stronger Than Stock 1200 Clutch Spring (BT15) (% based on '91-'03 1200 OEM spring)
380lbs - 25% Stronger Than Stock 1200 Clutch Spring (BT25) (% based on '91-'03 1200 OEM spring)

Barnett HD-style Clutch Spring ¹³⁾