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1980 Ironhead Sportster Chopper

Clutch Rebuild

Posted by Justin on 10/5/2005
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Once I got it running and got a chance to spend a little time riding, I realized that the engine didn't seem to be fully pulling the wheels like it should so I'm tearing apart the clutch to replace the springs, friction plates, and steel plates. I found a good deal on Barnett Kevlar friction plates and Barnett steels at Jireh. I decided to use Barnett plates rather than generic oem in order to give this clutch every possible performance advantage, which it needs because the stroker engine presumably can generate a lot of torque. I'm also going to install a Tamer II while I'm in there, I've read that this helps smooth engagement, a big plus for a grabby old sportster clutch.

Images

Removing the Pl With the retaining ring gone they all slide out easily. You can even pull out the whole pack by grabbing the bolts and pulling outward. 1024 x 768 px (237 KB) 0 Comments		Side of the bik with the primary cover removed and clutch compression tool installed 1024 x 768 px (225 KB) 0 Comments
Clutch Compress Just a 1/4" thick steel bar with nonthreaded holes drilled through it for the 1/4" and 3/8" threaded stock 1024 x 768 px (186 KB) 0 Comments	Compressor Fron Total spent: around $5 at home depot. The real tool costs $80-100 1024 x 768 px (248 KB) 0 Comments	Starter Solenoi The gearshaft on the left is pushed forward by the solenoid to engage the starter motor to the outer ring on the clutch basket 1024 x 768 px (169 KB) 0 Comments
Clutch & Chain Another shot of the clutch prior to disassembly. The primary chain tensioner is the white plastic block at the lower left. 1024 x 768 px (214 KB) 0 Comments	Compression Too Nothing was threaded or welded, it's all being held in place by the nuts 1024 x 768 px (223 KB) 0 Comments	Compressing the Used a vicegrips to turn the threadstock and a wrench to hold the nut in place 1024 x 768 px (232 KB) 0 Comments
Bent Compressio I might have overdone the compression but the bar started to bend. I didn't want the thing exploding in my face so back to the bench for reinforcemen... 1024 x 768 px (239 KB) 0 Comments	Problem Solved Drilled a new bar to stack on the old one. Could have gotten more strength by bolting or welding them together but they held long enough to get it apart 1024 x 768 px (249 KB) 0 Comments	Bent but workin Both bars bent a little, probably because I overtightened the center "bolt" 1024 x 768 px (236 KB) 0 Comments
Ready to come a Removed the 6 locknuts.. ready to release the pressure 1024 x 768 px (193 KB) 0 Comments	Opening the Clu As the plate moves out the clutch springs are visible inside 1024 x 768 px (152 KB) 0 Comments	Disc & Springs The pressure is off, it's cake from here on out. I did notice that the bearing on the release disc feels kind of rough but it doesn't seem critical enough to warrant replacing 1024 x 768 px (225 KB) 0 Comments
Clutch Innards Just need to remove the retaining ring and pull out the plates 1024 x 768 px (233 KB) 0 Comments	Retaining Ring The ring came out easily with a flathead screwdriver 1024 x 768 px (193 KB) 0 Comments	DSCN7435.JPG 1024 x 768 px (180 KB) 0 Comments
Clutch Pack Here they are all stacked with the backing plate 1024 x 768 px (162 KB) 0 Comments	Splines Detail This is what I was hoping not to find - the clutch basket and inner hub are somewhat grooved from wear - hopefully I can get by without replacing them 1024 x 768 px (114 KB) 0 Comments	Inner Hub Splin They look slightly worse than the outer basket splines but not awful. This hub is a $100 part and the outer drum is $240. 1024 x 768 px (111 KB) 0 Comments
Inner Hub Splin 1024 x 768 px (98 KB) 0 Comments	Outer Hub Splin 1024 x 768 px (112 KB) 0 Comments	Stud Plate & Sp Looks to be in good enough condition, should get new spacers with the friction plate kit 1024 x 768 px (145 KB) 0 Comments
Friction Plates Not sure but going to guess these are oem. 1024 x 768 px (182 KB) 0 Comments	Steel Driven Pl The old steels would probably have worked fine but they are definitely worn and their rough edges suggest they are oem quality so the Barnett plates will be a big improvement. 1024 x 768 px (207 KB) 0 Comments	Friction Plate I don't have the new ones yet to compare but these definitely look old and worn and feel smooth on the surface. 1024 x 768 px (139 KB) 0 Comments
DSCN7448.JPG 1024 x 768 px (126 KB) 0 Comments

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1980 Ironhead Sportster Chopper

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