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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #21  
Old 19th March 2007
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Quote:
Originally Posted by cjburr View Post
You will need a new seal where the clutch cable goes into the primary. There is no need to remove the primary cover just to change the cable.

You just need to follow the post till the ramp is removed from the cable, and then unscrew the lower clutch cable from the primary cover.

Glad it helped you, Chris
I was wondering about that. I was going to ask a dumb question whether to use teflon paste or something like that. Never did get around to installing the clutch cable. Call my chicken.
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  #22  
Old 19th March 2007
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Here's the latest info on the clutch springs. I spoke with Kent at Energy One Clutches this AM. He tells me that they have two different springs for the Sportster, the first has 15% more force that stock which he tells me is 340 lbs with a new clutch pack. The second spring has 25% more force and that spring develops 380 lbs of force, again with a new clutch pack.

So if my grammer school math is correct a stock 1200 spring develops 300 lbs of force with a new clutch pack. One thing to note is that Kent said that those numbers are all based on pre '04 clutch springs so with that in mind one would assume that the newer springs are actually producing less force due to the design of the easy pull clutch spring.
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  #23  
Old 19th March 2007
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Received my extra plate clutch kit today and lo and behold....................

I'm an idiot

This kit comes with the 15% stronger diaphragm spring not the 25% stronger spring that I wanted.

Put a call in to Energy One and the tech guy is at lunch.....of course.

He is supposed to call me back and I will find out what kind of HP and torque this kit is designed for. Stupid me thought that the "Performance Kit" would have the best they had to offer, not the medium duty spring.

On the plus side the girl who answered the phone was very nice and even called me back to let me know that the tech guy would call me when he returned.

The outcome soon, Chris(this is what happens when you assume)
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  #24  
Old 20th March 2007
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cjburr, hope everything is going well with the clutch install. I think I will go the same route as you. Do you think the clutch spring compresser tool in a must or could you have done it without it. I just want to make sure before I order it since it is almost as expensive as the clutch! Thanks for any advice.

Jason
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  #25  
Old 20th March 2007
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nice job, can't wait for the install
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  #26  
Old 20th March 2007
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Default Install Complete

Talked to the tech rep at Energy One he said the extra plate kit with the 15% stronger plate is good to 130 to 135 HP. So I installed it

One thing that was changed from stock was the fact that you cannot run SYN3 in the case. Energy One said they had problems with slippage running SYN3. They recommended B&M Trick Shift ATF so that is what I put in it. You can buy it at AutoZone for $6.95 a quart.

I have some pics I'll post later, not quite as detailed but I have been at this for a while and wanted to ride

RESULTS: No slippage from a 3000rpm roll on in 5th on the highway.
Original problem solved.

Bike shifts smoothly with the B&M ATF in the case. Very snappy from just about anywhere in the rpm band, nail it around 4000rpm you better be holding on.

Passing cars on the highway just requires thinking about it.

Clutch pull definitely stronger than stock but very manageable, not that hard at all.

You will need the spring compressor tool, no way around it that I can see.

All in all a pretty simple job.
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  #27  
Old 20th March 2007
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you are the man cj. Very good writeup and will definately look back on this when i get my new clutch cable for the apes!
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  #28  
Old 20th March 2007
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One thing I forgot to add and it's a warning: The tech guy at Energy One said that if you plan on running the 25% stronger spring you need to upgrade to a billet pressure plate as the cast stock one is prone to breaking at that level of pressure.
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  #29  
Old 20th March 2007
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The real test is. What happens when you twist the throttle full at 3000. Does it wheelie CJ. I would not test that unless you are ready to smack your knee on the aircleaner. It is fun. Thanks to your post I now understand why the guy showed me a part of my dyno run to explain that I had no clutch slippage.
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  #30  
Old 20th March 2007
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This is a great write up.

Gunna make it a sticky!

Thanks Chris
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