Clunk washer fix

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Jul 18, 2008 | 11:48 AM

#11

carltex

Thread Starter

Road Warrior

Joined: Jul 2006

Posts: 1,643

Likes: 1

From: Allen, Texas

RE: Clunk washer fix

Great, my warranty runs out Tuesday. May have to bite the bullet and take it in.

Jul 18, 2008 | 12:18 PM

#12

blkfalc4

Tourer

Joined: Jul 2005

Posts: 314

Likes: 1

From: Mass.

RE: Clunk washer fix

I just tourqed mine to 80ft-lb and clunk is gone.
&nbsp\\;
BTW, I heard it was harder than the original and the tourque on it was increased.

Jul 18, 2008 | 12:33 PM

#13

davidsdad

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Joined: May 2007

Posts: 1,260

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From: Flatwoods Kentucky

RE: Clunk washer fix

You do not bend the new washer like the original, you just tourqe 80 ft-lbs

Jul 18, 2008 | 12:51 PM

#14

Black Bart

Road Master

Joined: Aug 2006

Posts: 1,189

Likes: 3

From: Massachusetts

RE: Clunk washer fix

Carl,
The ID, OD and thickness of washer number 45727-08 is 1.030"ID, 2.0"OD and 0.62" thick.&nbsp\\; Hope this helps.
&nbsp\\;
Bart&nbsp\\;

Jul 18, 2008 | 12:56 PM

#15

Black Bart

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Joined: Aug 2006

Posts: 1,189

Likes: 3

From: Massachusetts

RE: Clunk washer fix

Carl,
Let's try this again\\; OD is 2.0" ID is 1.030" and thickness is 0.062".&nbsp\\; Sorry about the last post.&nbsp\\; Hope you read this one before you make the washer.
&nbsp\\;
Bart

Jul 18, 2008 | 02:23 PM

#16

JRK5892

Banned

Joined: Mar 2007

Posts: 19,481

Likes: 25

From: Chicago suburbs (Elgin/Schaumburg)

RE: Clunk washer fix

cool now i know not to bend it up just torque to 80ft lbs!

Jul 18, 2008 | 03:03 PM

#17

badbs101

Road Master

Joined: Aug 2006

Posts: 756

Likes: 0

From: MN

RE: Clunk washer fix

Here's a link to the correct part numbers.&nbsp\\;https://www.hdforums.com/m_2806355/tm.htm\\\\\\; I bought the washer myself and brought it to the local HD dealer and had them install it per service bulletin 1215A.&nbsp\\;\\\\\\; (warranty fix)&nbsp\\;\\\\\\; I would have done it myself but the job called for a 1.5" socket to tighten the nut.&nbsp\\;\\\\\\; I couldn't find anything bigger than 1.25 around the house.
&nbsp\\;\\\\\\;
It pays to buy the washer in advance as they probably won't have it in stock and will probably try to fix it by overtightening the nut.&nbsp\\;\\\\\\; The new washer is a bit thicker and doesn't have a locking tab to bend.

Jul 18, 2008 | 03:51 PM

#18

streetbobby

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Joined: Sep 2007

Posts: 53

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RE: Clunk washer fix

I turned the adjuster nut down half a turn, torqued the top nut to 65 LBs and bent the washer.....rides better than when it was new!....and no more clunk!