When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
When I got my 2004 it had been passed from one owner that did a lot of work to it, onto another owner that knew nothing and a third owner that knew nothing. Now I've been piecing together her puzzles. I do know the original owner put in a HD big bore kit. Cylinders are HD, so I'm assuming it was an HD big bore kit. I had to measure with a straw to the top of the spark plug hole to figure out it was not an 883 any longer. My first real clue came when rebuilding the carb and finding 1200 jet sizing and plugs were not rich.
OK, so she's had some things done to her. Maybe cams too? Hard to say without tearing into her. My real concern is the clutch. When I did the original fluids change I wasn't looking closely for any signs of brass and rivet plate disintegration. I suppose it's quite possible that the original owner did upgrade the clutch as well, but no way to know for sure. What would you do in this situation? Tear into the clutch with a new kit in hand? Tear into it and see what lurks beneath (more down time)? Leave it until it shows signs of an issue? Drain the fluids and see if there are any signs?
If you were going to put in a clutch kit, what would you choose?
"Leave it until it shows signs of an issue? Drain the chaincase fluid and see if there are any signs?"
Either of these seem the best place to start. Part of big bore upgrading 2004 and later bikes is replacing the 883 clutch diaphragm spring, so if that was done, perhaps the spring plate was taken out. How is your clutch operation? Quick engagement and possible chirping? I've heard there is less friction zone without the spring plate, but I still have my spring plate and have never ridden a Sportster with the "extra plate" kit, so this is just what I've read of other's experiences. Heavier clutch lever, quick engagement (narrow friction zone), intermittent chirping in first gear takeoff are mostly what I've read.
John
Last edited by John Harper; May 1, 2025 at 06:34 PM.
I have no other Harley comparisons to make. I've also been spoiled for quite a while with hydraulic clutches on other bikes. Last bike I had with a cable clutch was a 1993 Honda XR650L. I'll just say the clutch engagement currently seems fine. The other day I got caught in crawling traffic for probably 20 minutes and it seemed to get a little more grabby, but not significantly worse. Clutch pull does seem heavy, but not bad. Again, I survived that 20 minutes of stop and go. No chirping of any kind that I've noticed. I'm sure I'm being a overly paranoid, but it seems the earlier '04 bikes made more mention of the rivet plate issues.
I've learned in life is never assume anything & prepare for the worst. When I bought my low mileage 2018 it was pretty evident it hadn't had anything done to it other than a couple simple bolt on's ( a sissybar & led headlight) . At 7700 miles I decided to change the clutch to an energy one clutch with the oil change. Its an easy job and while the clutch looked fine that came out I now have the piece of mind it wont blow up on me if I abuse it. As for your situation, well if I was in your shoes I'd at minimum get a gasket set & some oil. I'd pull the primary put eyes on it & see what you have. If its a stock clutch I'd toss it & its its not I'd put it back with new oil & gasket with the confidence that now you know for sure what you have even if you don't know the name brand.
I've been happy with my energy one clutch, the pull honestly isn't hardly any harder than a stock one and I've messed up my left hand badly twice (Both cases have contributed to arthritis in my left hand.) So if I can handle it you probably can too. As for power delivery it isn't grabby & I haven't perceived any loss of effective engagement on the lever. I do THINK it seems to put down slightly more power to the wheel afterwards but without a drag strip run before & after there is really no telling. It's more a seat of the pants thing.
I read over on XLF that the Energy One diaphragm spring is a better design than the H-D and allows an easier pull. The guy over on XLF is pretty savvy, but he did not post up any photos to show what the differences were between the E1 and the H-D springs.
I read over on XLF that the Energy One diaphragm spring is a better design than the H-D and allows an easier pull. The guy over on XLF is pretty savvy, but he did not post up any photos to show what the differences were between the E1 and the H-D springs.
John
I looked to see if I took any photos of the install & unfortunately I didn't so I don't have any to post of it or the spring. This is the kit I bought though. https://energyoneclutches.com/produc...ion-tool-combo the tool ain't cheap & who knows how many times in your life you'll actually need it, but it did make it easy.
I wonder what the stock diaphragm looks like in comparison.
John
Ask & ye shall receive. Funny thing is I knew exactly where it was as I was cleaning out under my work bench this weekend. I kept the old one incase I #1 didn't like the new one, & #2 ever met someone who needed one in a pinch. Plus the icecream tub with a bit of old gear oil in doesn't take up much space.
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Slideshow: The bar-and-shield logo shows up on far more than motorcycles, some of the company's most unexpected products have nothing to do with riding.
Slideshow: From the troubled AMF years to modern misfires, these bikes earned reputations for reliability issues, questionable engineering, or disappointing performance.
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Slideshow: The Swiss custom shop has taken a Harley Softail and stretched it into something so long and low that it looks closer to a rolling sculpture than a conventional motorcycle.
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Slideshow: A standard cruiser becomes an intricate metal canvas in the hands of a Swiss custom house known for pushing Harley-Davidson platforms far beyond their factory brief.
Slideshow: Harley-Davidson's challenges aren't abstract; they show up in dropping shipments, shrinking dealer traffic, and strategic decisions that aren't yet translating into growth.
Clutch Concerns
