Before you buy a new clip run a pick around the groove to make sure there isn't something in there keeping the clip from going into place.


Even if that clip rotated I don't think it will cause a problem.

 

I would think the slot is damaged where the clip wont fit or crud in it , if you could get the clip in properly i would run it but be looking for a deal on a new one

Dave

 

Ok couple things. I've always suspected the fit of the ring but I never had an issue and bought an OEM one so assumed I was overthinking. Watch this video. The clip groove is fine it's the clip that doesn't fit tight around it. If the opening tab area of the clip is positioned over the broken hub portion, the clip pops out on one side when I pull the clutch lever. There seems to be all of the pressure pushing on the opening areas of the clip. Here's the video and a picture of what happens when I pull the clutch and the clip isn't rotated away from the broken area. I don't get it unless I got a bad retaining ring I bought 37909-90 think they are all the same

 

Yeah that ain't right.
You shouldn't be able to shift the snap ring around like that.
Either you got the wrong size or you compressed it too much when you installed it.
You can try expanding it but I think getting a new one is a better idea.

 

Par for the course I guess. Not sure that anything has gone correctly for this bike. I bought the clip at the local HD dealer. I ordered one online in the package this time instead so maybe the dealer sold me a aftermarket one? Not sure but I'll compare them when it comes in. All the pressure is on the opening of the clip because it's not seating. I wonder if the new one doesn't seat right I could cut a small piece off the old one and have it welded to the other one to close the gap and keep it seated but I'm hoping the new one fits properly and I don't have to consider this hack.

 

Before you do that I'd suggest you put some snap ring pliers on it and instead of trying to collapse it try to expand the opening.
Maybe you can stretch the snap ring out so that it will fit.

 

I would put some heat on the snap ring before I tried that, because it doesn't look heat treated unless it's just galvanized. If it heat treated I wouldn't try bending it all, even with heat. You go re-arranging the grain structure of that snap ring and you may find yourself in an even bigger bind.

 

I'm going to be holding that front brake extra tight at intersections now waiting for it to pop at the worst possible time.

 

Might as well put a suicide clutch on it if you're that worried. You didn't loose a lot of metal there... put the right sized snap ring in it and see what happens. It will probably be fine.

 

I'm fairly certain it is made out of spring steel.


kp877 you might want to read this
http://www.practicalmachinist.com/vb...nnealed-76439/