Question doing 95" bore upgrade
Question doing 95" bore upgrade
I am in the middle of performing big bore upgrade, cleaning heads, valve job to the 01 RKC. I received in the kit a clutch diaphragm spring and some various o-rings for the oil pump and cam/crank area. Since I dont see directions to this anywhere with the kit or on the internet, can someone tell me, am I just supposed to replace the o-rings and diaphragm as they are needed for this big bore upgrade? I can understand the spring, maybe it changes pressure on the plates to compensate for the increased power, but the 0-rings do not make sense. Unless they send them in case you are doing a cam replacement which many people do at this time, but mine was already done by previous owner.
Also, if the diaphragm is to be swapped, do i perform this as a clutch pack but stop once i get to the diaphragm and then reassemble? Also, I am putting on a new clutch cable as mine started to wear through the nylon sheath excessively and was pinching pretty bad. I can NOT find the instructions to just replacing a clutch cable either at the transmission end. I would be very grateful if someone could point out the directions and/or method. I do have the service manual but it merely talks about adjusting the clutch and replacing clutch pack. I see nothing talking specifically about replacing the cable, cable connections at the transmission or diaphragm replacement. I do not assume, that has gotten me into some big pickles in the past.
Thanks!
Also, if the diaphragm is to be swapped, do i perform this as a clutch pack but stop once i get to the diaphragm and then reassemble? Also, I am putting on a new clutch cable as mine started to wear through the nylon sheath excessively and was pinching pretty bad. I can NOT find the instructions to just replacing a clutch cable either at the transmission end. I would be very grateful if someone could point out the directions and/or method. I do have the service manual but it merely talks about adjusting the clutch and replacing clutch pack. I see nothing talking specifically about replacing the cable, cable connections at the transmission or diaphragm replacement. I do not assume, that has gotten me into some big pickles in the past.
Thanks!
Road Master
Joined: Apr 2010
Posts: 824
Likes: 2
From: O'fallon IL
Most of these kits come with extra parts and o-rings. As long as you replace the ones you remove then don't worry about it.
Do you have a factory service manual? There should be a section in there that explains how to replace clutch cable. I know both my 03 and my 09 manuals have it. First you'll need to drain the transmission. The right side of the tranny housing (clutch release cover) has to come off to replace the cable. Unfortunately, you usually have to remove the exhaust to get the housing off. Once you get the cover off you'll see a big retaining ring inside the cover that holds everything i place. Removing the retaining ring will allow you to release the end of the cable. Be careful, there's some little ball bearings in there. Once you release the end of the cable, you can unscrew it from the housing and remove.
Don't forget to replace the clutch cover gasket and tranny oil. Hopefully, you find this in your manual. It's not difficult - just time consuming.
Do you have a factory service manual? There should be a section in there that explains how to replace clutch cable. I know both my 03 and my 09 manuals have it. First you'll need to drain the transmission. The right side of the tranny housing (clutch release cover) has to come off to replace the cable. Unfortunately, you usually have to remove the exhaust to get the housing off. Once you get the cover off you'll see a big retaining ring inside the cover that holds everything i place. Removing the retaining ring will allow you to release the end of the cable. Be careful, there's some little ball bearings in there. Once you release the end of the cable, you can unscrew it from the housing and remove.
Don't forget to replace the clutch cover gasket and tranny oil. Hopefully, you find this in your manual. It's not difficult - just time consuming.
Most of these kits come with extra parts and o-rings. As long as you replace the ones you remove then don't worry about it.
Do you have a factory service manual? There should be a section in there that explains how to replace clutch cable. I know both my 03 and my 09 manuals have it. First you'll need to drain the transmission. The right side of the tranny housing (clutch release cover) has to come off to replace the cable. Unfortunately, you usually have to remove the exhaust to get the housing off. Once you get the cover off you'll see a big retaining ring inside the cover that holds everything i place. Removing the retaining ring will allow you to release the end of the cable. Be careful, there's some little ball bearings in there. Once you release the end of the cable, you can unscrew it from the housing and remove.
Don't forget to replace the clutch cover gasket and tranny oil. Hopefully, you find this in your manual. It's not difficult - just time consuming.
Do you have a factory service manual? There should be a section in there that explains how to replace clutch cable. I know both my 03 and my 09 manuals have it. First you'll need to drain the transmission. The right side of the tranny housing (clutch release cover) has to come off to replace the cable. Unfortunately, you usually have to remove the exhaust to get the housing off. Once you get the cover off you'll see a big retaining ring inside the cover that holds everything i place. Removing the retaining ring will allow you to release the end of the cable. Be careful, there's some little ball bearings in there. Once you release the end of the cable, you can unscrew it from the housing and remove.
Don't forget to replace the clutch cover gasket and tranny oil. Hopefully, you find this in your manual. It's not difficult - just time consuming.
Thanks for the info! Love you guys on this site, teamwork is everything. I am doing this so that I will learn more about my bike and about engines, clutches, fuel injections, lol, etc etc etc!
Tourer
Joined: Jul 2007
Posts: 497
Likes: 8
From: New Egypt, NJ
The clutch spring is simpler than that: Remove the derby cover and then replace the spring. It's a tight squeeze geting it in and out that way, but it does fit. I just changed the spring on my RK and my wife's Dyna this way. Just don't drop any bolts; then you'll be pulling the primary cover.
As for the clutch replacement, I don't drain the trans unless it's due for service. I put a couple of rags under the trans and a drain pan to catch what leaks out, then top it off when I'm done. If done when on the side stand you won't lose all that much.
As for the clutch replacement, I don't drain the trans unless it's due for service. I put a couple of rags under the trans and a drain pan to catch what leaks out, then top it off when I'm done. If done when on the side stand you won't lose all that much.
Road Captain
Joined: Mar 2008
Posts: 732
Likes: 2
From: SE Alabama
Another trick for dealing with the fluid loss is put bike on 2x4 and let it tilt further over on kickstand side and then fluid loss is minimal
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The clutch spring is simpler than that: Remove the derby cover and then replace the spring. It's a tight squeeze geting it in and out that way, but it does fit. I just changed the spring on my RK and my wife's Dyna this way. Just don't drop any bolts; then you'll be pulling the primary cover.
As for the clutch replacement, I don't drain the trans unless it's due for service. I put a couple of rags under the trans and a drain pan to catch what leaks out, then top it off when I'm done. If done when on the side stand you won't lose all that much.
As for the clutch replacement, I don't drain the trans unless it's due for service. I put a couple of rags under the trans and a drain pan to catch what leaks out, then top it off when I'm done. If done when on the side stand you won't lose all that much.
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Road Master
Joined: Apr 2010
Posts: 824
Likes: 2
From: O'fallon IL
Thanks! I did find it in 2-21 of the manual. I am new and still learning the logic to the harley manuals. I have the pipes off, doing a big bore upgrade, remember! lol. So to answer my diaphragm question, is it as simple as i think, remove primary cover, remove the retaining bolt/nut, swap diaphragm spring, return bolt/nut, tighten to torgue, replace cover, fill with fluid.... I hope it is!
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