Click below to see common issues by year of bike.
PROBLEM: CLUTCH WILL NOT RELEASE
- Check cable adjustment. Some after-market cables stretch so you lose cable pull. Readjust cable and leave some free play.
- Pressure plate not properly adjusted - Put the bike in neutral and spin hub. Check for parallel alignment.
- Check all 10 clutch pins for notches. If so, plates will not move freely.
- Pull on the outer basket to make sure its not loose, then spin to make sure it spins freely and concentric.
- Check friction plates and look at the ten holes. Make sure they are not egg shaped and steel plates for rolled over edges and flatness.
If they are the anti-rattle type, check all rivets and make sure small ball bearings do roll. If they appear to be loose, do not reuse them. Replace with a type that do not have all those extra pieces like our part, BTS-5. That is the last thing you want is all those moving pieces floating around in there. If steels are warped and blued, they should be replaced. Sometimes you could bead blast and reuse.
- Check the stack height. It should be 1.575. If the kit is older, it will be under. If it is under 1.500, it should be replaced. Part #BT-5. Frictions and steels included.
- If plates appear to be glazed, sometimes for a quick fix you can bead blast steel plates and on the friction plates rub a piece of emery cloth or sand paper #220 - #400 grit in a circular motion on a flat surface to remove high spots and glazed area. IT IS VERY IMPORTANT TO PRE-SOAK PLATES even if you are running it dry. Why, for the initial start up even though the bike is in neutral, those plates are still rubbing against each other and will cause them to reglaze again. Just scuffing is not good, what you want is full contact area.
- Check and make sure all springs are evenly compressed and adjusted.
- What should you presoak them in?
- Inspect all moving parts very carefully and always remember heat will destroy things.
- Check the stack height 1.575 is new. Don't go below 1.500.
- Pressure plate adjustment for proper and even.
- Check all 10 springs for height.
- Glaze plates.
- 1941-84 replacement kit - friction plates and steels with a pre-measured stack height BT-5 Performance Kit - Extra Plate Kit - BTX-5 includes 6 frictions, 5 steels and 10 springs.
1984 1/2 - 1989
- Check cable adjustment. Since this is a two-piece cable, adjustment is very easily lost.
- The manufacturer went to a diaphragm spring which is one big spring and there is a setting adjustment (a) being the softest. If it tends to slip, move adjuster plate to (b) position if no better, move to (c) that is the strongest position.
- Remove plates and check stack height. Should be .885 - .900 new. If under size, needs to be replaced with part #BT-9. Kit includes frictions and steels.
PROBLEM: IMPROPER ENGAGEMENT
- Check friction plates for glazed area and steel plates for flatness. This is very important. If frictions are glazed, and steel are warped, and spring is on (c) adjustment, you should replace frictions and steels included in kit BT-9 order.
90-97 BIG TWIN; 91 & LATER SPORT
- These bikes again have a two-piece cable so proper cable adjustment is very important.
- Check steels and frictions for warpage and discolored steels. If steels are discolored, it has reached a very high heat and is time to replace with part #BT-11 or #BTX-11. Diaphragm spring could have lost some tension if it slips at high RPM. Most likely, it's spring tension. Replace with part #BT-15. If frictions are warped, replace with part #BT-11. For the performance extra plate kit with 9 frictions, 8 steels, and the BT-15 spring, order part #BTX-11.
Check your owners manual for minimum stack height. New fresh kit is 1.275 to 1.290
Receive technical assistance by calling (602) 438-7052 or e-mail us at email@example.com. We will be glad to help no matter whose parts you have! We do not care whose clutch you bought, we're here to help. Energy One is not just selling parts, we sell engineered performance parts, manufactured by US. Race proven and tested and used by Belt Drives Ltd. and Rivera Engineering/Primo.