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Harley Davidson Sportster Models 2009. Service Repair Manual - page 64

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Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 5-2. Clutch Cable Adjuster Mechanism

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Screw (6)

Clutch inspection cover

Hex lockplate and spring

Nut

Ramp assembly (see items 15-18)

Coupling

Quad ring

Primary cover

Adjusting screw assembly

10. Primary cover gasket
11. Screw w/ captive washer (16)
12. O-ring
13. Clutch cable end
14. Cable end fitting
15. Outer ramp
16. Ball (3)
17. Inner ramp
18. Retaining ring

Figure 5-3. Clutch Release Mechanism and Primary Cover

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2009 Sportster Service: Drive/Transmission 5-5

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Screw, 1/4-20 x 1 15/16 in. w/ captive washer (16)

Screw, 1/4-20 x 3/8 in. w/ O-ring (2)

Screw, 1/4-20 x 5/8 in. TORX w/ captive washer
(6)

Shifter shaft oil seal

Figure 5-4. Outer Primary Cover

Primary Chain Adjuster

See

Figure 5-5

. Remove lock nut (1) from adjuster screw (4).

Turn adjuster screw out of threaded boss in primary cover (3).

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Lock nut

Nylon sealing surface

Primary cover

Adjuster screw

Shoe

Slot

Plate

Figure 5-5. Primary Chain Adjuster Assembly

INSTALLATION

Primary Chain Adjuster

See

Figure 5-5

. Inspect primary chain adjuster shoe (5).

If badly worn or damaged, it must be replaced.

Position adjuster inside primary cover (3) with closed side
of shoe against cover. Thread adjuster screw (4) all the
way into tapped boss at bottom of primary cover.

At outside of cover, thread lock nut (1) onto adjuster screw
with nylon sealing surface (2) toward cover. A 1/4-inch
allen wrench may be inserted into end of adjuster screw
to hold it while threading lock nut.

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5-6 2009 Sportster Service: Drive/Transmission

Primary Cover

See

Figure 5-4

. Install new shifter shaft oil seal (4).

See

Figure 5-3

. Install new gasket (10) on primary cover

(8).

Install primary cover and gasket using sixteen screws with
captive washers (11). Tighten to 100-120 in-lbs (11.3-13.5
Nm) in the sequence shown in

Figure 5-6

Remove foreign material from magnetic drain plug. Install
plug and tighten to 14-30 ft-lbs (19.0-40.7 Nm).

Install new o-ring (12) over cable end fitting (14) of clutch
cable lower section. Turn fitting clockwise to install into
primary cover (8). Tighten fitting to 36-60 in-lbs (4.1-6.8
Nm).

Fit coupling (6) over cable end (13) with rounded side of
coupling inboard and ramp connector button outboard.
With retaining ring side of ramp assembly (5) facing
inward, place hook of ramp around coupling button and
rotate assembly counterclockwise until tang on inner ramp
(17) fits in slot of primary cover (8).

Thread nut (4) on adjusting screw assembly (9) until slot
of screw is accessible with a screwdriver. Fit nut hex into
recess of outer ramp (15) and turn adjusting screw coun-
terclockwise until resistance is felt. Back off adjusting
screw 1/4 turn.

Slide lockplate and spring (3) onto flats of adjusting screw.
If necessary, turn adjusting screw clockwise slightly so
that lockplate slides onto flats while also fitting within
recess of outer ramp.

Fill transmission to proper level with fresh lubricant. See

1.14 TRANSMISSION LUBRICANT

10. Install new quad ring (7) in groove of primary cover. Verify

that quad ring is fully seated in groove.

11. Install six screws (1) to secure clutch inspection cover (2)

to primary cover. Tighten screws in a crosswise pattern
to 84-108 in-lbs (9.5-12.2 Nm).

12. See

Figure 5-2

. Turn cable adjuster (2) clockwise away

from jam nut (3) until slack is eliminated.

13. See

Figure 5-7

. Pull clutch cable ferrule away from clutch

lever bracket to check free play. Turn cable adjuster as
necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) free play
between end of cable ferrule and clutch lever bracket.

14. See

Figure 5-2

. Hold cable adjuster (2) with 1/2 inch

wrench. Using 9/16 inch wrench, tighten jam nut (3)
against cable adjuster. Cover cable adjuster mechanism
with rubber boot (1).

15. Install left side rider footrest and mounting bracket

assembly.

Models equipped with mid-mount foot controls:
see

2.40 RIDER FOOT CONTROLS: XL MODELS

EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

for

installation procedure.

Models equipped with forward foot controls: see

2.41 RIDER FOOT CONTROLS: XL MODELS
EQUIPPED WITH FORWARD CONTROLS

for

installation procedure.

16. Adjust primary chain tension. See

1.12 PRIMARY CHAIN

When tension is set correctly, tighten lock nut to 20-25 ft-
lbs (27.1-33.9 Nm).

17. Install rubber washer and gear shift lever on shifter shaft.

Secure with pinch screw and washer. Tighten to 16-20 ft-
lbs (21.7-27.1 Nm).

18. Open left side cover. See

2.20 LEFT SIDE COVER

Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)

19. Connect positive (+) battery cable to battery positive (+)

terminal. See

1.17 BATTERY MAINTENANCE

20. Close left side cover.

21. Connect negative (-) battery cable to stud on engine

crankcase behind starter motor assembly. See

1.17 BATTERY MAINTENANCE

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Figure 5-6. Outer Primary Cover Screw Tightening

Sequence

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2009 Sportster Service: Drive/Transmission 5-7

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Clutch cable

Cable ferrule

Clutch lever bracket

Adjustment range

Figure 5-7. Clutch Freeplay: Adjust for 1/16-1/8 in. (1.6-3.2

mm) Gap Between Ferrule and Bracket

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5-8 2009 Sportster Service: Drive/Transmission

5.4

CLUTCH RELEASE MECHANISM

REMOVAL AND DISASSEMBLY

NOTE

For clutch adjustment procedure, see

1.13 CLUTCH

To prevent accidental vehicle start-up, which could cause
death or serious injury, remove main fuse before pro-
ceeding. (00251b)

Unplug main fuse. See

6.38 MAIN FUSE

Models equipped with mid-mount foot controls: remove
left side rider footrest and mounting bracket assembly.
See

2.40 RIDER FOOT CONTROLS: XL MODELS

EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

See

Figure 5-8

. Slide rubber boot (1) on clutch cable

adjuster (2) upward to expose adjuster mechanism.
Loosen jam nut (3) from adjuster. Turn adjuster to shorten
cable housing until there is a large amount of freeplay at
clutch hand lever. See

1.13 CLUTCH

See

Figure 5-9

. Remove six screws (1) and clutch

inspection cover (2). Remove and discard quad ring (10).

Slide spring (3) with attached hex lockplate (4) from flats
of adjusting screw assembly (11).

Turn adjusting screw clockwise to release ramp and
coupling mechanism (6, 7, 8, 9, 12). As the adjusting screw
is turned, ramp assembly moves forward. Remove nut (5)
from end of adjusting screw.

Remove hook of ramp from cable end coupling (12).
Remove clutch cable end (15) from slot in coupling.

Remove and discard retaining ring (9) from ramp assembly
to separate inner ramp (8) and outer ramp (6). Remove
balls (7) from ramp sockets.

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Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 5-8. Clutch Cable Adjuster Mechanism

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2009 Sportster Service: Drive/Transmission 5-9

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10.

Quad ring

Screw (6)

11.

Clutch inspection cover

Clutch adjusting screw assembly

12.

Coupling

Spring

13.

Hex lockplate

Primary cover

14.

O-ring

Nut

15.

Outer ramp

Clutch cable end

16.

Cable end fitting

Ball (3)

17.

Inner ramp

Clutch cable

Retaining ring

Figure 5-9. Clutch Release Mechanism

CLEANING, INSPECTION AND REPAIR

See

Figure 5-9

. Thoroughly clean all parts in cleaning

solvent and dry with a clean, lint-free cloth.

Inspect three balls (7) of release ramp and coupling
mechanism (6, 7, 8, 9, 12) and ball socket surfaces of
inner ramp (8) and outer ramp (6) for wear, pitting, surface
breakdown and other damage. Replace parts as neces-
sary.

Check hub fit of inner and outer ramps. Replace ramps if
excessively worn.

Check clutch cable assembly (17) for frayed or worn ends.
Replace cable if damaged or worn. See

2.31 CLUTCH

CONTROL

Change or add transmission fluid if necessary. See

1.14 TRANSMISSION LUBRICANT

ASSEMBLY AND INSTALLATION

See

Figure 5-9

. Assemble inner and outer ramps.

Apply a light coat of multi-purpose grease to balls (7)
and ramps (6, 8).

Insert balls in sockets of outer ramp (6).

Install inner ramp (8) on hub of outer ramp with tang
on inner ramp 180° from hook of outer ramp.

Install new retaining ring (9) in groove of outer ramp
hub.

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5-10 2009 Sportster Service: Drive/Transmission

Install ramp assembly.

Fit coupling (12) over cable end (15) with the rounded
side inboard, the ramp connector button outboard.

With retaining ring side of ramp assembly facing
inward, place hook of ramp around coupling button.

Rotate assembly counterclockwise until tang on inner
ramp fits in slot of primary cover.

Secure assembly in place.

Thread nut (5) on adjusting screw assembly (11) until
slot of screw is accessible with a screwdriver.

Fit nut hex into recess of outer ramp and turn
adjusting screw counterclockwise until resistance is
felt. Back off adjusting screw 1/4 turn.

Slide spring (3) with hex lockplate (4) onto flats of adjusting
screw. If necessary, turn adjusting screw clockwise slightly
so that lockplate slides onto flats while also fitting within
recess of outer ramp.

Install new quad ring (10). Verify that quad ring is fully
seated in groove of primary cover (13). Install six screws
(1) to secure clutch inspection cover (2) to primary cover.
Tighten screws in a crosswise pattern to 84-108 in-lbs
(9.5-12.2 Nm).

See

Figure 5-8

. Turn cable adjuster (2) clockwise away

from jam nut (3) until slack is eliminated.

See

Figure 5-10

. Pull clutch cable ferrule away from clutch

lever bracket to check free play. Turn cable adjuster as
necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) free play
between end of cable ferrule and clutch lever bracket.

See

Figure 5-8

. Hold cable adjuster (2) with 1/2 inch

wrench. Using 9/16 inch wrench, tighten jam nut (3)
against cable adjuster. Cover cable adjuster mechanism
with rubber boot (1).

Models equipped with mid-mount foot controls: install
left side rider footrest and mounting bracket assembly.
Tighten footrest bracket mounting screws to 45-50 ft-lbs
(61-68 Nm). See

2.40 RIDER FOOT CONTROLS: XL

MODELS EQUIPPED WITH MID-MOUNT CONTROLS

2.42 RIDER FOOT CONTROLS: XR MODELS

for

installation procedure.

10. Install main fuse. See

6.38 MAIN FUSE

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Clutch cable

Cable ferrule

Clutch lever bracket

Adjustment range

Figure 5-10. Clutch Freeplay: Adjust for 1/16-1/8 in. (1.6-3.2

mm) Gap Between Ferrule and Bracket

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2009 Sportster Service: Drive/Transmission 5-11

5.5

PRIMARY DRIVE AND CLUTCH: XL MODELS

GENERAL

The purpose of the clutch is to smoothly engage and disengage
the engine from the rear wheel for starting, stopping, and
shifting gears.

See

Figure 5-11

. The clutch is a wet, multiple-disc unit with

one spring plate (8), six steel plates (9), and eight fiber (friction)
plates (10) stacked alternately in the clutch shell (2). The order
of plate assembly, from inboard to outboard, is as follows:

F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F

(F = Friction plate, St = Steel plate, Sp = Spring plate)

Table 5-4. Clutch Troubleshooting

REMEDY

CAUSE (CHECK IN FOLLOWING ORDER

Symptom

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment

Clutch slips

Check service wear limits. Replace plates.

Worn clutch plates

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment

Clutch drags

Replace release ramps and/or balls.

Worn clutch release ramps or balls

Replace clutch steel plates.

Warped clutch steel plates

Replace clutch gear or hub as required.

Blade worn or damaged clutch gear splines

Drain lubricant to correct level.

Overfilled primary

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5-12 2009 Sportster Service: Drive/Transmission

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15.

Release plate

Retaining ring

16.

Clutch shell and sprocket

Retaining ring

17.

Diaphragm spring

Ball bearing

18.

Retaining ring

Spring seat

19.

Retaining ring

Clutch hub

20.

Spring washer

Retaining ring

21.

Inner ramp

Mainshaft nut

22.

Spring plate

Outer ramp

23.

Nut

Steel plate (6)

10.

24.

Friction plate, fiber (8)

Locking plate

25.

11.

Clutch adjustment spring

Pressure plate

12.

26.

Adjusting screw

Ball (3)

27.

13.

Clutch cable coupling

Bearing

14.

28.

Retaining ring

Clutch pack (consists of items 8, 9, 10)

Figure 5-11. Clutch Assembly: XL Models

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2009 Sportster Service: Drive/Transmission 5-13

REMOVAL

TOOL NAME

PART NUMBER

SPROCKET LOCKING LINK (883 CC)

HD-38362

SPROCKET LOCKING LINK (1200 CC)

HD-46283

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

NOTE

See

Figure 5-11

. If replacement of clutch pack (28) is the only

service work required, perform REMOVAL Steps 1 and 4 only,
and then proceed to the NOTES under DISASSEMBLY.

Disconnect negative (-) battery cable from stud on engine
crankcase behind starter motor assembly. See

1.17 BATTERY MAINTENANCE

Open left side cover. See

2.20 LEFT SIDE COVER

Remove positive (+) battery cable from battery positive
(+) terminal. See

1.17 BATTERY MAINTENANCE

Remove primary cover, as described under

5.3 PRIMARY

CHAIN ADJUSTER

. Discard primary cover gasket.

NOTES

•

See

Figure 5-12

. In the next step, you will be positioning

the SPROCKET LOCKING LINK (1) on the engine and
clutch sprockets. Make sure you do not position the
sprocket locking link too close to the shifter shaft (2). If
the sprocket locking link contacts the shifter shaft while
you are exerting force to loosen the engine sprocket nut,
the sprocket locking link may damage the shifter shaft
and/or the engine crankcase.

•

To determine the correct sprocket locking link for your
application, refer to tool table.

See

Figure 5-12

. Install SPROCKET LOCKING LINK (883

CC) (Part No. HD-38362) or SPROCKET LOCKING LINK
(1200 CC) (Part No. HD-46283). Remove the engine
sprocket nut. Do not remove engine sprocket at this time.

See

Figure 5-11

. Remove large retaining ring (16).

Remove adjusting screw assembly (12, 13, 14 and 15)
from pressure plate (11).

NOTE

Transmission mainshaft nut (7) has left-hand threads. Turn nut
clockwise to loosen and remove from mainshaft.

Remove nut (7) and spring washer (6). Remove the clutch
assembly, primary chain and engine sprocket as an
assembly from the vehicle.

Inspect primary chain. If damaged or excessively worn,
remove it from engine sprocket and clutch assembly;
replace original primary chain with a new one.

Inspect stator and rotor. See

6.29 ALTERNATOR

. Replace

damaged parts as necessary.

NOTE

If replacement of primary chain is the only service work
required, proceed directly to

5.5 PRIMARY DRIVE AND

CLUTCH: XL MODELS, Installation

. Skip Step 1 and begin

with the NOTE preceding Step 2.

11502

Sprocket locking link

Shifter shaft

Figure 5-12. Using Sprocket Locking Link (Part No.

HD-46283 or HD-38362) to Loosen Engine Sprocket Nut

DISASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

NOTES

•

See

Figure 5-11

. If replacement of clutch pack (28) is the

only service work required, perform DISASSEMBLY Steps
2 - 5 and 7 only, and then proceed to the NOTE under
INSPECTION AND REPAIR.

•

Observe all WARNING and CAUTION statements which
apply to the steps specified.

See

Figure 5-11

. With clutch assembly removed from

primary chaincase, install adjusting screw assembly (12,
13, 14 and 15) into pressure plate (11), noting that two
tabs on perimeter of release plate (15) must be inserted
into corresponding recesses in pressure plate. Secure the
adjusting screw assembly with retaining ring (16).

Disassemble clutch using a spring compressing tool. The
diaphragm spring is compressed and, if removed without
proper tools can fly out, which could result in death or
serious injury. (00292a)

Thread the CLUTCH SPRING FORCING SCREW (Part
No. HD-38515-91) (1,

Figure 5-13

) onto the clutch

adjusting screw (12,

Figure 5-11

). Place the bridge (2,

Figure 5-13

) of SPRING COMPRESSING TOOL (Part

No. HD-38515-A) against diaphragm spring (17,

Figure 5-11

). Thread the tool handle (3,

Figure 5-13

) onto

end of forcing screw.

NOTE

Figure 5-11

. Turn compressing tool handle only enough to

remove retaining ring (19) and spring seat (18). Excessive

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5-14 2009 Sportster Service: Drive/Transmission

compression of diaphragm spring could damage clutch pres-
sure plate.

See

Figure 5-11

. With a wrench on the clutch spring for-

cing screw flats to prevent the forcing screw from turning,
turn handle clockwise until tool relieves pressure on
retaining ring (19) and spring seat (18).

Remove and discard retaining ring. Remove spring seat
from the groove in clutch hub (5) prongs. Remove the
assembly of diaphragm spring (17), pressure plate (11),
adjusting screw components (12, 13, 14 and 15) and
compressing tool.

Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the clutch
adjusting screw. Remove spring seat and diaphragm
spring from pressure plate assembly.

Remove retaining ring (16) and adjusting screw assembly
from pressure plate. If necessary, disassemble adjusting
screw assembly by removing retaining ring (14), and then
separating the remaining adjusting screw components
(12, 13, and 15).

Remove the clutch pack (28) from the clutch hub. The
clutch pack consists of one spring plate (8), six steel plates
(9), and eight friction (fiber) plates (10).

NOTE

See

Figure 5-11

. Due to the possible damage to the bearing

(3), the clutch hub (5) and shell (2) assembly should not be
disassembled unless the bearing, hub or shell require
replacement. If the assembly is pressed apart, the bearing
must be replaced.

If necessary, disassemble clutch shell and clutch hub as
follows:

Remove retaining ring (1) from inboard end of clutch
hub (5).

Using an arbor press, separate clutch hub from
assembly of clutch shell (2), bearing (3), and retaining
ring (4).

Remove retaining ring (4) from groove in clutch shell.

Press on the inboard side of bearing (3) outer race
to remove bearing from clutch shell.

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Forcing screw

Bridge, Spring Compressing Tool

Handle

Open-end wrench

Figure 5-13. Compressing Clutch Diaphragm Spring

INSPECTION AND REPAIR

NOTE

See

Figure 5-11

. If replacement of clutch pack (28) is the only

service work required, perform all INSPECTION AND REPAIR
steps (except Step 2f), and then proceed to the NOTES under
ASSEMBLY.

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

See

Figure 5-11

. Wash all parts, except the friction (driven)

plates (10) and bearings (3 and 13), in a non-volatile
cleaning solution or solvent. Blow parts dry with low pres-
sure compressed air.

Examine the clutch components as follows:

Inspect all clutch plates for wear and discoloration.

Inspect all fiber plates (10) for worn lining surfaces or
checked or chipped linings.

Inspect each steel (drive) plate (9) for grooves.

Place each steel plate on a flat surface. Using a feeler
gauge, check for flatness in several places. Replace
any plates that are damaged, or warped more than
0.006 in. (0.15 mm).

See

Figure 5-14

. Wipe the lubricant from the eight

friction plates and stack them on top of each other.
Measure the thickness of the eight stacked friction
plates with a dial caliper or micrometer. The minimum

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2009 Sportster Service: Drive/Transmission 5-15

thickness must be 0.661 in. (16.79 mm). If the thick-
ness is less than specified, the friction plates and steel
plates must be discarded, and a new set of both fric-
tion and steel plates must be installed.

See

Figure 5-11

. Inspect clutch shell ball bearing (3)

for smoothness by rotating clutch shell while holding
clutch hub. If bearing is rough or binds, it must be
replaced.

See

Figure 5-15

. Check the primary chain sprocket

(3) and the starter ring gear (4) on the clutch shell (1).
If either sprocket or ring gear are badly worn or dam-
aged, replace the clutch shell.

Check the slots (5, 6) that mate with the clutch plates
on both clutch shell and clutch hub (2). If slots are
worn or damaged, replace shell and/or hub.

See

Figure 5-11

. Check the diaphragm spring (17)

for cracks or bent tabs. Install a new spring if either
condition exists.

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Figure 5-14. Measuring Clutch Friction Plates

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Clutch Shell

Clutch hub

Primary chain sprocket

Starter ring gear

Clutch hub slots

Clutch shell slots

Figure 5-15. Checking Clutch Hub and Clutch Shell

ASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

NOTES

•

See

Figure 5-11

. If replacement of clutch pack (28) is the

only service work required, perform all ASSEMBLY Steps
except 2, 5 and 6, and then proceed to the NOTE under
INSTALLATION.

•

Observe all WARNING and CAUTION statements which
apply to the steps specified.

Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.

See

Figure 5-16

. If the clutch hub (1) and clutch shell (4)

was disassembled, press new ball bearing (3) into clutch
shell and secure bearing with a new retaining ring (2).
Press inboard end of clutch hub into clutch shell bearing
and secure with a new retaining ring (5) on end of hub.

See

Figure 5-11

. The clutch pack (28) consists of one

spring plate (8), six steel plates (9) and eight friction (fiber)
plates (10). Install clutch pack into clutch shell in the fol-
lowing order:

F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F

(F = Friction plate, St = Steel plate, Sp = Spring plate)

See

Figure 5-11

. Place pressure plate (11) onto clutch

pack (28).

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5-16 2009 Sportster Service: Drive/Transmission

If disassembled, assemble bearing (13) and adjusting
screw (12) in release plate (15); secure with new retaining
ring (14).

Install adjusting screw assembly (12, 13, 14, 15) into
pressure plate (11), noting that two tabs on perimeter of
release plate (15) must be inserted into corresponding
recesses in pressure plate. Secure adjusting screw
assembly with new retaining ring (16).

Position diaphragm spring (17) with its concave side facing
inboard (toward pressure plate), onto pressure plate
assembly.

Position spring seat (18) with its flat, larger outer diameter
side facing inboard (toward diaphragm spring).

Install a new retaining ring (19) onto convex (outboard)
side of diaphragm spring.

10. See

Figure 5-11

and

Figure 5-13

. Thread the CLUTCH

SPRING FORCING SCREW (Part No. HD-38515-91) (1,

Figure 5-13

) onto the clutch adjusting screw (12,

Figure 5-11

). Place the bridge (2,

Figure 5-13

) of SPRING

COMPRESSING TOOL (Part No. HD-38515-A) against
diaphragm spring (17,

Figure 5-11

). Thread the tool handle

(3,

Figure 5-13

) onto end of forcing screw. Do not tighten

compressing tool against diaphragm spring at this time.

11. See

Figure 5-17

. Align square openings of pressure plate

and diaphragm spring (1) so the assembly can be installed
over prongs of clutch hub (2). Place assembly of spring
seat (5), retaining ring (3), diaphragm spring, pressure
plate, adjusting screw components (4) and compressing
tool onto clutch hub and against clutch pack (28,

Figure 5-11

NOTE

See

Figure 5-11

. Turn compressing tool handle only enough

to install spring seat (18) and retaining ring (19). Excessive
compression of diaphragm spring (17) could damage clutch
pressure plate (11).

12. See

Figure 5-13

. Place an open-end wrench (4) on the

clutch spring forcing screw (1) flats to prevent the forcing
screw from turning.

13. See

Figure 5-11

. Turn compressing tool handle clockwise

until diaphragm spring (17) compresses just enough to
install spring seat (18) and retaining ring (19) into the
groove in clutch hub (5) prongs.

14. With retaining ring positioned against flange face (outboard

side) of spring seat and fully seated in groove of clutch
hub, carefully loosen and remove compressing tool.

NOTE

When the compressing tool is removed, the diaphragm spring
will move outward forcing the spring seat up into the inside of
the retaining ring. The spring seat provides an operating surface
for the diaphragm spring at the same time preventing the
retaining ring from coming out during operation.

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Clutch hub

Retaining ring

Ball bearing

Clutch shell

Retaining ring

Figure 5-16. Clutch Hub and Shell Assembly

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Diaphragm spring (pressure plate below)

Prongs on clutch hub

Retaining ring

Adjusting screw assembly

Spring seat

Figure 5-17. Spring Seat Installation

INSTALLATION

TOOL NAME

PART NUMBER

SPROCKET LOCKING LINK (883 CC)

HD-38362

PRIMARY DRIVE LOCKING TOOL
(1200 CC)

HD-46283

NOTE

See

Figure 5-11

. If replacement of clutch pack (28) is the only

service work required, perform INSTALLATION last step only.

See

Figure 5-11

. Remove retaining ring (16). Remove

adjusting screw assembly (12, 13, 14, 15) from pressure

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2009 Sportster Service: Drive/Transmission 5-17

plate (11). This allows installation of the transmission
mainshaft nut and washer.

NOTE

Prior to installing engine sprocket nut and transmission main-
shaft nut, thoroughly clean threads of engine sprocket shaft,
engine sprocket nut, transmission mainshaft and mainshaft
nut to remove any oil that might contaminate and interfere with
locking agent.

Prior to installing engine sprocket nut and transmission
mainshaft nut, thoroughly clean threads of engine sprocket
shaft, engine sprocket nut, transmission mainshaft and
mainshaft nut to remove any oil that might contaminate
and interfere with locking agent.

NOTE

See

Figure 5-18

. In the next step, you will be positioning the

SPROCKET LOCKING LINK (883 CC) (Part No. HD-38362)
or PRIMARY DRIVE LOCKING TOOL (1200 CC) (Part No. HD-
46283) (1) on the engine and clutch sprockets. Make sure you
do not position the sprocket locking link too close to the shifter
shaft (2). If the sprocket locking link contacts the shifter shaft
while you are exerting force to tighten the engine sprocket nut,
the sprocket locking link may damage the shifter shaft and/or
the engine crankcase.

See

Figure 5-18

. Install SPROCKET LOCKING LINK (883

CC) (Part No. HD-38362) or PRIMARY DRIVE LOCKING
TOOL (1200 CC) (Part No. HD-46283).

Apply two or three drops of LOCTITE Threadlocker 262
(red) onto threads of engine sprocket shaft.

Install engine sprocket nut. Tighten to 240-260 ft-lbs (326-
353 Nm).

NOTE

See

Figure 5-19

. Washer (2) must be installed with the word

"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.

See

Figure 5-19

. Apply two or three drops of LOCTITE

Threadlocker 262 (red) onto threads on end of transmis-
sion mainshaft. Install spring washer (2) and mainshaft
nut (1) (left-hand threads) on transmission mainshaft.
Tighten nut to 70-80 ft-lbs (95.0-108.6 Nm).

Remove SPROCKET LOCKING LINK.

See

Figure 5-20

. Install adjusting screw assembly (1) in

pressure plate, noting that two tabs on perimeter of release
plate must be inserted into corresponding recesses in
pressure plate. Secure assembly with a new retaining ring
(2).

Install primary cover using new gasket. See

5.3 PRIMARY

CHAIN ADJUSTER

10. Adjust primary chain and clutch. See

11. Fill transmission with GENUINE HARLEY-DAVIDSON

FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT. See

1.14 TRANSMISSION LUB-

RICANT

12. Connect battery. See

1.17 BATTERY MAINTENANCE

sm01266

Sprocket locking link

Shifter shaft

Figure 5-18. Tighten Engine Sprocket Fastener (typical)

sm01355

Mainshaft nut

Spring washer

Clutch hub

Figure 5-19. Mainshaft Nut and Washer

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5-18 2009 Sportster Service: Drive/Transmission

sm01268

Adjusting screw assembly

Retaining ring

Figure 5-20. Clutch Adjusting Screw Assembly and

Retaining Ring

HOME

2009 Sportster Service: Drive/Transmission 5-19

5.6

PRIMARY DRIVE AND CLUTCH: XR MODELS

GENERAL

The purpose of the clutch is to smoothly disengage and engage
the engine from the rear wheel for starting, stopping and shifting
gears.

See

Figure 5-21

. The clutch is a wet, multiple-disc clutch with

steel plates and fiber (friction) plates stacked alternately in the
clutch shell. The pack consists of seven fiber plates, seven
steel plates, one narrow fiber plate, one damper spring and
one damper spring seat. The fiber plates (clutch driving plates)
are keyed to the clutch shell, which is driven by the engine
through the primary chain. The steel plates (clutch driven
plates) are keyed to the clutch hub, which drives the rear wheel
through the transmission and secondary drive belt.

When the clutch is engaged (clutch lever released), the dia-
phragm spring applies strong force against the pressure plate.

The pressure plate then presses the clutch plates together
causing the plates to turn as a single unit. The result is that
the rotational force of the clutch shell is transmitted through
the clutch plates to the clutch hub. As long as the transmission
is set in a forward gear, power from the engine will be trans-
mitted to the rear wheel.

When the clutch is disengaged (clutch lever pulled to left
handlebar grip), the pressure plate is pulled outward (by clutch
cable action) against the diaphragm spring, thereby com-
pressing the diaphragm spring. With the pressure plate
retracted, strong inward force no longer squeezes the clutch
plates together. The fiber plates are now free to rotate at a
different relative speed than that of the steel plates (i.e. Slip-
page between the clutch plates occurs). The result is that the
rotational force of the clutch shell is no longer fully transmitted
through the "unlocked" clutch plates to the clutch hub. The
engine is free to rotate at a different speed than the rear wheel.

Table 5-5. Clutch Troubleshooting

REMEDY

CAUSE

CHECK
ORDER

SYMPTOM

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment.

Clutch slips

Check service wear limits. Replace plates.

Worn clutch plates.

Check and adjust clutch release mechanism.

Incorrect clutch release adjustment.

Clutch drags

Replace release ramps and/or balls.

Worn clutch release ramps or balls.

Replace clutch steel plates.

Warped clutch steel plates.

Replace clutch gear or hub as required.

Blade worn or damaged clutch gear splines.

Drain lubricant to correct level.

Overfilled primary.

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5-20 2009 Sportster Service: Drive/Transmission

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