CLUTCH TALK & TIPS
CLUTCH SERVICING & TROUBLESHOOTING TIPS FOR HARLEY DAVIDSON
CLUTCH SYMPTOMS:

- Slippage:
- Clutch controls improperly adjusted.
- Insufficient clutch spring tension.
- Worn friction plates.
- Warped frictions or steels.
- Improper cable adjustment.
- Drags or Does Not Release:
- Clutch controls improperly adjusted.
- Clutch spring tension too tight, coil binds.
- Friction plates gumming up.
- Clutch shell keys or hub studs badly worn.
- Clutch plates warped (metal or frictions).
- Clutch cable collapsing, improperly adjusted.
- Improper adjustment on primary chain/belt.
- Chatters:
- Clutch hub liner friction plate rivets loose or broken.Z
- Clutch spring disc too flat (diaphragm).
- Friction or steel plates worn or warped.
- Glazed or burned friction plates.
- Improper adjustment on primary chain/belt.
- Frayed/stretched clutch cable.
- Hard To Shift:
- Improperly adjusted primary chain/belt.
- Improperly adjusted drive chain (rear wheel).
- Clutch has too much drag (see above).
- Gearbox problems.
- Cable adjustment and/or stretch.
- Improper primary oil (wet-type).


Tip #1
When doing any repair, it is wise to buy an owners service manual. Use this manual for reference, specs, and measurements so that the job goes smoothly and quickly, otherwise a one hour job might take all day. Take the time to do it right.

Tip #2
Before installing the clutch, check the following:

- Check the inner shell for bearing grooves (replace if necessary).
- Grooves on clutch surface of shell (replace shell).
- Rivets broken or have come loose (repair or replace).
- Notched steel plate stops (replace shell).

Check the bottom of the case for parts, pieces, chunks, shavings, etc. You might have other problems!
NOTE: If the primary chain or belt it not properly adjusted to service manual specs, it can cause dragging problems to the clutch shell.

Tip #3
Check clutch hub for severe problems, such as:

- Notched studs (drive hub) - replace.
- Notched pins (clutch hub) - replace.
- Worn clutch hub liner or rivets - replace.
- Worn or collapsed spring bearing plate - replace.
- Notched hub assembly, rollers or retainer - replace.


NOTE: Sometimes the gear box bearings can be worn and cause these problems.

Tip #4
- Check clutch friction, drive plates and springs.
- Check for burned or bent drive plates by stacking the plates like "pancakes." Holding them horizontally up to the light, check for gaps. Plates can also be checked with a straight edge or surface plate. Replace bad plates.

- If all drive plates are flat, glass bead blast them before installing the new friction plates. You can also "rough" up the surface with a fine emery or sand paper. Never bead blast friction plates.

- Measure the clutch pack for stack height by measuring all friction and drive plates in one total stack. This measurement should meet manufacturer specs and any replacements should conform to this stack height.

- Friction plates are simple to check out. If they are burned, glazed, grooved, oil soaked (dry type), gummed up, measuring too thick or too thin, or have no oil grooves on friction surface (wet type) - replace them.

- Springs - You can go with heavy duty springs or you can check to make sure yours are in good shape. To do this, measure the height of the spring. If it is less than the service manual calls for, replace it. (See note.)
NOTE: Heavy duty replacement springs may vary from manufacturers specs in size and length, but should work at manufacturers suggested adjustment. Also, spring setting will vary when using aluminum pressure plates/spring retainers.

Tip #5
Lever and cable control.
Most Harley Davidson lever positions are set at about 1/8" of play. However, the best positioning of the lever is where it works best for you -