I own a 2001 Hugger with 20,000 miles on it. Really happy w/ the bike until I started hearing a lot of noise chatter from the Primary Case. From reading all the Posts here at the XLForum it looks like I may have a problem with the infamous "riveted Spring Plate" coming apart. I plan on keeping the bike for awhile so I thought about doing the Barnett Extra Plate upgrade (HDP-11EPK).
I've already done the cheap fixes: Fluid changes, Primary chain and clutch adjustments but the thing still chatters and drags somewhat.
Is a clutch change something I can do myself? Also, what tools and any recommended parts will I need for it? I do own the HD service manual for my bike.
Don't know about your model but my 93 had a bearing go bad in the clutch adj-sounded like gravel for a while and then the clutch would not stay in adj. pretty easy fix matched bearing at car quest pressed it out with a spark plug socket and re installed. new fluid and gasket now is smooth as silk!! worth a shot to check. T.
I've been riding my Sporty for the last 5 1/2 years and when I changed the transmission oil this last time it looked more watery. I change it every 5000 miles. I still used the HD Sports-Trans Fluid and regular HD 20w-50 oil in my bike.
My clutch problem started one day last week when I started hearing a whine noise from the primary. That noise soon grew to a chattering noise on the 3rd day. After that I went through the XL Forum for ideas about what it was and it looks like the simple easy fixes have not cured it.
I'll be looking into getting one of the clutch removal tools and be waiting to hear from anyone on how a clutch is changed on a Sporty or what not to do. I do have the manual so I just need some basic pointers on what to look for once I break open the Primary Case. I never done a clutch job so this will be pretty interesting.
I made a call to Barnett Clutch this morning and they said changing the clutch wasn't too hard. They said the hard part was removing the primary cover and hopefully I don't strip any of the screws.
Now I'm gonna order the parts and the clutch removal tool. I don't know if I have the talent or tools to fabricate my own though.... Anyway I'll probably use the tool again or help my brother on his 05 Sportster one day.
Thanks - I'll post back my results for future reference to anyone.
Also, I'll work on learning to add pictures to my posts.