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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #1  
Old 1 Week Ago
porch_hornet porch_hornet is offline
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Default Clutch assembly question on 77 XLCH

I recently bought a 77 XLCH that had been sitting since at least 2006. One of the issues with the bike is that the clutch lever would not engage the clutch at all. I pulled the primary cover to look around. Everything looked ok except that the thrust bearing was missing. I found it in a box of hardware that came with the bike, but I'm not sure that's all that is needed. If you have experience with this clutch assembly on this model year, please watch my video (link below) and comment.

My latest thinking is that I misread the diagram I was looking at, and all that is needed is the thrust bearing, but I'm open to educated input.

Thanks,

https://youtu.be/aHrbf7MEwuw
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Old 1 Week Ago
1Scooter 1Scooter is offline
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Put the collar thrust bearing into the release disk bearing. There is no spacer because it moves in and out. Make sure to check the clearance between the outer clutch drive plate and the release dish. 1974 and later measurement is 1/8" min. That spacing measurement is adjusted with different length stud spacers.
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porch_hornet porch_hornet is offline
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Thanks brother. I found the diagram in the service manual that describes what you're saying for 74 and later. I've got 1/4 inch between the back of the releasing disk and the Outer drive plate.
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Old 2 Days Ago
porch_hornet porch_hornet is offline
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Default

My buddy and got the primary squared away today. The clutch now pulls and actuates as it should. There was also the tensioner that I replaced with one of the self adjusting ones. The little peg that the foot peg uses to stay properly spaced over the shift lever was buggered and full of JB Weld. We used a drill press to reestablish a new set of holes and a rolled tension pin to replace the original. All works well. Last step will be to re-mount the primary cover. Got a new James gasket set. Should be doing that this weekend.
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brucstoudt brucstoudt is offline
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nice job with that.
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