Removed the primary cover last night - nothing obvious to report...

Except for the awful burned up smell. It is so strong that my garage reeks of burned up Harley parts.

Working on getting an Energy One clutch pack, new gaskets, fluids, and the compression tool. I expect this will fix the problem.

With the bike in 1st gear, spinning the rear tightens up the slack on the primary chain. Looks like the transmission is in good order.

 

How has your charging system been working? Typically that awful smell is the Stator showing signs of breaking down and smoking.

It could very well just be burnt clutch. There's clues like poor charging for one, or your slipping clutch, and / or burned looking and nasty smelling discs, which is what you seemed to be focused on now.

Be sure to check the clutch hub where's it mounted for cracks or breaks.

I'm sure you'll get to the bottom of it inside the primary.

 

Yeah, it's not my Sportster, so I can't attest to the charging system's performance. I too though the stator could be a possible cause, but none of that would cause the bike to not move while shifting.

Given the symptoms and signs, I am pretty sure it's the clutch. Once I have the clutch removed, I'll check over the hub and other relevant components.

Appreciate the tips!

 

The Energy 1 clutch showed up yesterday with the clutch compression tool. I was able to remove the stock clutch, and luckily, the brass rivets were 100% in tact. Friction discs were a little worn, but not excessively so.

Once I had the clutch removed, I was able to spin the clutch hub freely and the back tire was spinning without issue. Seems the transmission is fine.

Once the owner drops of his service manual that he just bought, I'll be pulling the entire drive assembly to check the clutch shell/clutch hub, just to be sure those pieces are good.

From this information, do you guys think the clutch is the cause of this not moving? Each clutch disc smelled terribly burnt up.

 

Sounds like you've found the culprit and tell your buddy if he wants to do burnouts in his driveway that's what it'll cost him

 

Sounds like from the smell you found the owner was trying hard to feather the clutch lever to keep that tire spinning.

 

The bike is all back together, with the Energy 1 clutch installed.

Everything is back to normal, and the drivetrain is back in running order.

Guess that turned out to be an expensive burnout...!

Thanks again guys for all the help and pointers - that is what makes this such a great forum.