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Clutch Rebuild

« 1980 Ironhead Sportster Chopper

(Clutch)

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.

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Side of the bike 1024 x 768 pixels (225 KB) 0 Comments with the primary cover removed and clutch compression tool installed	Clutch Compressor Tool 1024 x 768 pixels (186 KB) 0 Comments Just a 1/4" thick steel bar with nonthreaded holes drilled through it for the 1/4" and 3/8" threaded stock	Compressor Front View 1024 x 768 pixels (248 KB) 0 Comments Total spent: around $5 at home depot. The real tool costs $80-100
Starter Solenoid Gear 1024 x 768 pixels (169 KB) 0 Comments The gearshaft on the left is pushed forward by the solenoid to engage the starter motor to the outer ring on the clutch basket	Clutch & Chain Tensioner 1024 x 768 pixels (214 KB) 0 Comments Another shot of the clutch prior to disassembly. The primary chain tensioner is the white plastic block at the lower left.	Compression Tool Detail 1024 x 768 pixels (223 KB) 0 Comments Nothing was threaded or welded, it's all being held in place by the nuts
Compressing the Clutch 1024 x 768 pixels (232 KB) 0 Comments Used a vicegrips to turn the threadstock and a wrench to hold the nut in place	Bent Compression Bar 1024 x 768 pixels (239 KB) 0 Comments 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...	Problem Solved 1024 x 768 pixels (249 KB) 0 Comments 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
Bent but working 1024 x 768 pixels (236 KB) 0 Comments Both bars bent a little, probably because I overtightened the center "bolt"	Ready to come apart 1024 x 768 pixels (193 KB) 0 Comments Removed the 6 locknuts.. ready to release the pressure	Opening the Clutch 1024 x 768 pixels (152 KB) 0 Comments As the plate moves out the clutch springs are visible inside
Disc & Springs Removed 1024 x 768 pixels (225 KB) 0 Comments 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	Clutch Innards 1024 x 768 pixels (233 KB) 0 Comments Just need to remove the retaining ring and pull out the plates	Retaining Ring Removed 1024 x 768 pixels (193 KB) 0 Comments The ring came out easily with a flathead screwdriver
Removing the Plates 1024 x 768 pixels (237 KB) 0 Comments 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 pixels (180 KB) 0 Comments	Clutch Pack 1024 x 768 pixels (162 KB) 0 Comments Here they are all stacked with the backing plate
Splines Detail 1024 x 768 pixels (114 KB) 0 Comments 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	Inner Hub Splines 1024 x 768 pixels (111 KB) 0 Comments They look slightly worse than the outer basket splines but not awful. This hub is a $100 part and the outer drum is $240.	Inner Hub Splines 1024 x 768 pixels (98 KB) 0 Comments
Outer Hub Splines 1024 x 768 pixels (112 KB) 0 Comments	Stud Plate & Spacers 1024 x 768 pixels (145 KB) 0 Comments Looks to be in good enough condition, should get new spacers with the friction plate kit	Friction Plates 1024 x 768 pixels (182 KB) 0 Comments Not sure but going to guess these are oem.
Steel Driven Plate 1024 x 768 pixels (207 KB) 0 Comments 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.	Friction Plate Closeup 1024 x 768 pixels (139 KB) 0 Comments 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 pixels (126 KB) 0 Comments

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