Just found out my clutch pack order was cancelled because "technical problem", so I have to re-order.

That gives me some time.

I think I'll go ahead and do this, since I'm on stand-by for now.

 

Energy One is another option, extra plate pack BTX-11 or BTX-11 SP(with Spring)

 

Omaha, check the bolt holes, are they blind?

 

Good question. Anyone know?

My guess is they go through the cases. But that's just a guess.

Good grief this has drug on! Too many other things going on this summer!

Clutch parts came in last week. Got that installed. Went to put in the primary chain, and my torque wrench felt wrong. Felt like both the clutch and comp nuts were under torqued.

So the next day I took it to a tool shop. Tested fine. I'm to the point of seeing monsters under my bed, it seems.

Another day lost.

Went to install that plate on the clutch that holds the adjuster bolt. Snap ring didn't look good. Looked sprung. Installed it anyway. No good. Didn't come close to filling the slot.

So off to Harley for a new one. $13.53 for that. Damn. Even the parts guy was embarrassed.

Another day lost.

Got it buttoned up the rest of the way last night. Went to start it. Click Battery is dead. Or at least weak enough it won't turn it over.

Dug out my fancy pants tender for my fancy pants battery. Left it on overnight.

This morning it's flashing red. Says the battery is a gonner.

So now I've got an old (conventional) battery on a charger. It won't fit in the bike, but I can use it to verify that the battery really is the problem.

Hopefully, that's it.

We'll see.

In another day.

 

The saga continues

As for the torque wrench feel...maybe you're stronger than you think.

 

Can't speak to later transmission cases but on your '90 Touring, all the internal inner primary bolts thread into blind holes, engine and trans.

 

Time to put a bow on this one.

FINALLY back together. New battery arrived today. The Antigravity guys were good to me. Mine was about a month away from being out of (prorated) warranty, and they let me swap it out at a very deep discount.

Found out the hard way that I'd over tightened the pinion shaft bolt. That was a bit of a head scratcher. After a half dozen tries reinstalling the outer primary, I decided to RTFM. It was right there: Reinstall pinion bolt and torque to 3 to 6 ft lbs. That got it.

This bike had never had a sumping problem. Until now. Holy *********. First start it unloaded a good quart+ onto the floor. What a mess.

Gave her a quick 20 mile shakedown run. The new belt pulley ratio is wonderful. Sits right at 3200 RPM at 75 MPH. Shouldn't have waited until the old one broke before making that change.

The new clutch is total butter. Smooth.

Thanks to the Evo crew here for all the advice and ideas along the way. This group is the best!