So its been quite awhile since you started the clutch upgrade....
Did you finish it? Any notes or other observations?

thanks,

T.

 

Never got around to ordering the new clutch. Still on the stock clutch.

 

Clutch kit finally ordered. Should be here in a few days. I want the piece of mind of getting rid of a potential failure point with that riveted clutch plate HD installs in our bikes...


I am getting ready for this...



Steps outline in workshop manual:

Section 5.3 (page5-4) for Primary Cover removal
Section 5.4
For Removal of clutch pack: Page 5-8 ; Step 1-4 and Page 5-10 ; Steps 2,3,4,5,and 7
For Assembly of clutch pack: Page 5-12 ; Step 1,3,4,7,8,9,10,11,12,13

Part numbers of what it is required: I order most of it through Amazon and saved a few $$

Gaskets I got as a , but here is the breakdown with parts number
Primary Cover Gasket - Part Number: 34955-04
Inspection Cover Gasket - Part Number: 34990-08
Derby Cover Gasket (quad ring) - Part Number: 25463-94A
O-rings - Part Number: (2) 11171 for Inspection cover, (1) 11105 for Oil drain plug, (1) 11179 for Clutch cable
Shift Bushing - Part Number: 40574-06 (not sure if I needed, but just in case)
Shifter Shaft Oil Seal - Part Number: 37107-06
2 quarts Formula+ primary lubricant - Part Number: 62600004 (Only one is needed but I want to change the oil again in about 500-1000 miles)
Retaining Ring - Part Number: 37908-90 (#21 in my parts diagram. Recommended to have a new one ready to use when installing everything back)
Clutch pack: going with Energy One -
And the tool (must have the right tools for the job) -


Total was 189.83 for the parts listed including shipping (minus the oil and retaining ring, that I will buy locally).

Also ordered all the parts to do the Fat Bob wheels install - Thread on that here: New Fat Bob Wheels on 48?

 

Parts and tools are starting to come in...

 

Looks like I have everything now for the clutch job. Gasket just arrived...

 

Good to see updates from you, sir.

 

Thank you. I know that for many all the fun is riding... for me that is only half the fun... I get a lot of pleasure from just working on the darn thing... can't leave it alone. Well, the clutch is just a preventive measure... but not the wheels... I could have continue to use the current setup for many years...but could not leave it alone as I had this desire to go with tubeless setup since I got the bike.

I will start the work in the clutch this afternoon after work.



There are several threads on it but I will still take photos and share my experience with it.

Threads that I am using as guidance:

Found one here: Sportster extra plate clutch kit writeup

And found another one in the other forum: 06 Clutch Install

 

Rack arrived...quick photo and then it goes to the shelf for next trip... Still kicking myself for giving away the one I had... well, heck, I regret getting rid of the Nightster it was attached to...





And on the clutch work. What is the first thing you must do? Put the stickers on the toolbox of course!

 

On to the clutch...

First I need to remove the floorboard and shift linkage







Not sure if this goes in one way, but did not wanted to take chances... used some white liquid paper to mark the shaft and linkage so it goes back the same way when installing...



Bolts out



Assembly out

 

Loosen clutch cable adjustment





Drained primary oil



Loosen chain tensioner - I followed the recommendation from Chris on just loosen enough to turn so that I can get it back to the previous position quickly.



Remove cover





Remove spring with retainer nut



Using a small screwdriver (because it will need to go inside the nut to completely get it out), turn the adjuster screw clockwise until the nut comes off...





Slide out the ramp assembly and unhook from cable coupling













At this point you could remove the clutch cable... but all the threads and posts about this mentions that you can leave it in and avoid dealing with another seal... since the bike has less than 4K miles, I left it in place.

Now to remove the 16 bolts that hold the primary cover in place



I had made this from the cardboard that the new gasket came in... turns out that there was no need... in my motorcycle, all 16 bolts are the same length.