Clutch and shift lever replacement?
Thread Starter
|
6th Gear
Joined: May 2014
Posts: 11
Likes: 0
From: Quad Cities, IL
Clutch and shift lever replacement?
I have a 1996 FLHTCI that my shift lever on the transmission is really sloppy and cant be tightened anymore. Also my clutch is out of adjustment travel. It creeps when pulled in. (could the cable be stretched too much?) I am wanting to know if I need any special tools to do this job. I will replace the shift arm which I already purchased. What all do I need to change the clutch? I see so many options. Extra plates etc. I would just like to have it all before I start really soon. Thanks
Seasoned HDF Member
Joined: Jan 2011
Posts: 157,518
Likes: 57,070
From: Michigan 15 Minutes East Of Hell
Changing the lever on the shaft of the transmission can be a task. Quite often I've seen that taking out the pinch bolt, using a lubricant on another bolt to clean out the threads, cleaning thoroughly with some Brake Clean and installing a new bolt with a bit of Loc-Tite and torquing to spec will resolve the problem. I've done this successfully on several scooters and it is A LOT EASIER than replacing the lever. You could also consider using a "Better Lever" but they are quite pricey. https://betterlever.com/how_to.php
Seasoned HDF Member
Joined: Mar 2010
Posts: 21,114
Likes: 7,638
From: Poolville
I have not seen a cable stretch while disengaging the clutch but would consider it to be out of adjustment. Properly adjust the clutch and cable first then check your clutch shaft movement, it should be around .070" to .080" follow this link to adjust.
then measure the movement. If your problem still exists then it might be time to replace the clutch.
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
You should have about 1/8th" play in the lever.
At 77k I would open up the clutch basket and check the condition of your fibers and steels.
FYI Barnett fibers have about twice the fibers as stock fibers.
Trending Topics
Thread Starter
|
6th Gear
Joined: May 2014
Posts: 11
Likes: 0
From: Quad Cities, IL
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Seasoned HDF Member
Joined: May 2008
Posts: 21,173
Likes: 12,740
From: South Carolina
In order to replace the shift lever, you will be removing the primary cover.
That requires the removal of the clutch, primary chain and compensator.
You will need a locking tool to immobilize the clutch outer shell and the compensator sprocket.
The problem you describe with your clutch does not sound like a worn out clutch, because a worn out clutch will disengage easily.
The problem with a worn out clutch is that it won`t engage, or stay engaged.
It could be a warped plate or disc, a spring plate that is coming apart, or possibly some damage to the slider areas of the hub or outer shell.
It could also be a bad throwout bearing or stretched cable.
That requires the removal of the clutch, primary chain and compensator.
You will need a locking tool to immobilize the clutch outer shell and the compensator sprocket.
The problem you describe with your clutch does not sound like a worn out clutch, because a worn out clutch will disengage easily.
The problem with a worn out clutch is that it won`t engage, or stay engaged.
It could be a warped plate or disc, a spring plate that is coming apart, or possibly some damage to the slider areas of the hub or outer shell.
It could also be a bad throwout bearing or stretched cable.
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
It is also not wise to just start throwing parts at a problem.
Pull apart your clutch hub and look at what you have.
As Dan says there are several things that could be your problem but you won't know till you look.
Thread
Thread Starter
Forum
Replies
Last Post
Damion
Primary/Transmission/Driveline/Clutch
2
Mar 27, 2012 06:49 AM