Changing a clutch on an evo big twin

[Smoker03]

Guys, I've never done a clutch swap and was wondering if anyone has a link to a good how to. TIA Shane

[vlade]

Hello please post an intro in New to Community if you aint done so.
As to the clutch, best info I have seen would be a HD service manual for your year and model.

[Smoker03]

Thanks. Thats what I figured.

[Dave63]

What year bike? Doing a clutch is easy, compared to a lot of jobs. On Evo's and newer, there's a clutch pressure plate compression tool that's needed. 1991-1999 is one that can be made, and newer then that is a different type.

I've always taken the primary cover off, so draining the fluid and replacing it, and the gasket is in order. I usually waited to have to change the fluid, so I could get that done, and adjust the primary chain with everything apart at the same time.

Drain Primary.

Remove cover.

You undo your clutch cable adjustment (put slack in it ).

Remove the adjusting rod/adjuster bolt and plate

Install and compress the pressure plate with the tool.

Remove the retaining clip. (C-clip pliars)

Remove 6 retaining nuts off diaphram retainer.

Remove the Diaphram and retaining plate.

Remove the fiber and steel plates.

Check steel plates for warpage. Replace if warped.

Replace steel and fiber plates back in order after soaking fiber plates in primary fluid for about 15-20 minutes. May not be manditory, but I've always done it.

Reinstall face/pressure plate/retaining ring.

Readjust clutch basket. (turn in, till tension starts, back off 1/2 turn, lock nut)

Readjust cable for proper cable/lever play.

Reinstall cover/gasket.

Fill with fluid to bottom of clutch basket/pressure plate.

[Rockerbox1]

very inforamtive Dave....... easier than I thought it'd be
is a sporty about the same process? with the exception that the clutch cable mounts in the primary cover....

[Dave63]

Originally Posted by Rockerbox1

very inforamtive Dave....... easier than I thought it'd be
is a sporty about the same process? with the exception that the clutch cable mounts in the primary cover....

Yes, pretty much. The Big twins have a few diaphram retaining bolts as well (6) that the sporty doesn't have, and the sporty has a few spring seat rings that the big twin lacks, but if you take everyting apart and lay it out in order, all works out well.

The sporty also doesn't have the lock nut like the big twin, rather a flat blade screw driver slot on the end of the adjusting rod, and the outer nut that goes in to lick the surrounding collar in place.

The sporty needs that same tool, but 2 nuts, threaded stock and a metal "circle/ring" of metal and a welder and I can fab one up, in no time. I ended up buying a new one recently, adding to my HD specialty tool collection.....

[van_kerr]

Nice Tool ! ......... what are the dimensions ? I fancy trying to make one.