Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

outer ramp may be used in early engines, but
both parts must be installed, not mixed with
an early coupling or outer ramp.

1. Install the cable coupling onto the end of the clutch ca-
ble. Place the coupling in the ramp.
2. Apply grease to the ball and ramp surfaces (Figure 7)
and insert the balls into the ramp sockets.
3. Assemble the inner and outer ramps and install on the pri-
mary drive cover (C, Figure 6). Install the lockplate and the
ramp mounting screws. Tighten the screws securely. Bend
the lockplate tabs over the screws to lock them in place.
4. Install the primary drive cover as described in this chapter.
5. Adjust the clutch as described in Chapter Three.

PRIMARY CHAIN ADJUSTER

Removal/Installation

Refer to Figure 10.

1. Remove the primary drive cover as described in this
chapter.
2. Pull the chain pad (Figure 11), spring and washer from
the stud.
3. Replace the chain pad if worn severely or cracked. Also
check the carrier (3, Figure 10) and spring (2). Replace if
necessary.
4. Install by reversing the preceding steps.
5. Adjust the clutch (Chapter Three).
6. Adjust the primary chain (Chapter Three).
7. Refill the primary case and transmission with oil (Chap-
ter Three).

PRIMARY DRIVE/CLUTCH

Refer to Figure 12.

Special Tools

Complete disassembly of the clutch requires the use of a

clutch spring compression tool (part No. 34761-84). If the
compression tool is not available, remove the clutch intact
from the motorcycle and take it to a dealership for disas-
sembly and service. Do

not

attempt to disassemble the

clutch without the special tool.

Clutch/Primary Chain/Engine Sprocket Removal
(Clutch is Not Disassembled)

This procedure describes removal of the clutch, primary

chain and engine sprocket, which allows later clutch disas-
sembly as described in this section. If clutch disassembly
with the clutch mounted on the motorcycle is desired, refer
to

Clutch Disassembly on Motorcycle

in this section in this

chapter.

254

CHAPTER SIX

EARLY 1986

MODELS

LATE 1986-1990

MODELS

Outer ramp

Coupling

Flat

PRIMARY CHAIN ADJUSTER

1. Washer
2. Spring
3. Carrier
4. Chain pad
5. Screw
6. Stud

Refer to Figure 12.

1. Disconnect the negative battery cable (Chapter Twelve).
2. Remove the primary drive cover as described in this
chapter.
3. Remove the clutch adjusting screw snap ring (Figure
13) and remove the guide and adjusting screw assembly
(Figure 14).
4. Install a clutch holder (JIMS tool No. 2234 or equiva-
lent) to prevent engine sprocket rotation, then remove the
engine sprocket nut (A, Figure 15).
5. Remove the clutch snap ring (B, Figure 15) and spacer
behind the snap ring . Remove the clutch assembly, primary
chain and engine sprocket as an assembly.

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)

255

CLUTCH

1. Snap ring
2. Snap ring
3. Guide
4. Bearing
5. Adjusting screw
6. Snap ring
7. Spring seat (flat)
8. Spring seat (U-shaped)
9. Diaphragm spring

10. Inner clutch spring seat
11. Pressure plate
12. Friction plates
13. Steel plates
14. Spring plate
15. Snap ring
16. Spacer
17. Clutch hub
18. Snap ring
19. Bearing
20. Clutch shell
21. Snap ring

CAUTION

Do not attempt to disassemble the clutch as-
sembly after removing it from the motorcycle.
The clutch must be disassembled while
mounted on the engine.

6. Installation is the reverse of removal while noting the
following:

a. Apply threadlock (Loctite 242 or equivalent) to the

sprocket shaft threads.

b. Tighten the engine sprocket nut to 150-165 ft.-lb.

(203-223 N•m).

c. Adjust the primary chain (Chapter Three).

Clutch Disassembly on Motorcycle

This procedure describes disassembly of the clutch and

clutch plate removal while it is mounted on the motorcycle.
Engine sprocket and primary chain removal is not required.
Read this procedure completely before starting disassembly.
1. Disconnect the negative battery cable (Chapter Twelve).
2. Remove the primary drive cover as described in this
chapter.

WARNING

Do not attempt to disassemble the clutch as-
sembly without the use of a clutch spring
compression tool (part No. 34761-84). The
diaphragm spring (6,

Figure 12

) is held un-

der considerable pressure and will fly out if
pressure is not first removed.

3. Install the spring compression tool onto the clutch as-
sembly (Figure 16). Secure the compression tool per the
manufacturrer’s instructions.
4. Turn the adjusting screw counterclockwise until the
compression tool releases the pressure on the snap ring
(Figure 16). Remove the snap ring. Remove the nut and
compression tool.
5. Refer to Figure 12. Disassemble the clutch housing by
removing the following parts in order:

a. Adjusting screw assembly (Figure 14).
b. Outer clutch spring seats (Figure 17).
c. Diaphragm spring (Figure 18).

256

CHAPTER SIX

Adjusting screw

Nut

Snap ring

Compression tool

d. Inner clutch spring seat (Figure 19).
e. Pressure plate (Figure 20).

6. Remove four friction plates (Figure 21) and three steel
plates (Figure 22).
7. Remove the spring plate (Figure 23).
8. Remove the remaining friction and steel plates in the or-
der shown in Figure 12.

NOTE

Further removal steps are not required unless
it is necessary to separate the clutch hub and
shell assembly. Remove these parts as de-
scribed in this section.

Clutch Inspection

Refer to Figure 12.

1. Clean all parts, except friction and steel plates and bear-
ings, in a non-oil based solvent and thoroughly dry with com-
pressed air. Place all cleaned parts on lint-free paper towels.
2. Inspect the steel plates (A, Figure 24) for warp as shown
in Figure 25. Also measure the thickness of each plate. Re-
place all clutch plates; if any one plate is warped exces-
sively or is too thin. Refer to Table 1.
3. Inspect the friction plates (B, Figure 24) for wear or sur-
face damage. Measure the thickness of each plate (Figure 26)
and compare to specifications in Table 1. If a plate’s thickness
is within specifications but the oil grooves are worn flush with
the plate, replace the plates. Also check the friction plates for

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)

257

warp (Figure 27) and compare to the service limit in Table 1.
Replace all friction plates if any one plate is too thin or warped
excessively.
4. Inspect the spring plate (C, Figure 24) for cracks or
damage. Check for loose or damaged rivets. Replace the
spring plate if necessary.
5. Check the diaphragm spring for cracks or damage.
Check also for bent or damaged tabs. Replace the dia-
phragm spring if necessary.
6. A ball bearing is pressed into the clutch shell and the
clutch hub is pressed into the bearing. Hold the clutch hub
and rotate the clutch shell by hand. The shell should turn
smoothly with no sign of roughness or tightness. If the
clutch shell binds or turns roughly, the bearing is damaged
and must be replaced. Refer to Step 10.
7. The steel plate inner teeth mesh with the clutch hub
splines. Check the splines for cracks or galling. They must
be smooth for chatter-free clutch operation. If the clutch
hub splines are damaged, the clutch hub must be replaced;
refer to Step 10.
8. The friction plates (B, Figure 24) have tabs that slide in the
clutch shell grooves. Inspect the shell grooves for cracks or
wear grooves. The grooves must be smooth for chatter-free
clutch operation. If the clutch shell grooves are damaged or
worn severely, replace the clutch shell; refer to Step 10.
9. Check the primary chain sprocket and the starter ring gear
on the clutch shell for cracks, deep scoring, excessive wear
or heat discoloration. If either the sprocket or ring gear is se-
verely worn or damaged, replace the clutch shell; refer to
Step 10. If the sprocket is worn, also check the primary chain
and the engine sprocket as described in this chapter.
10. If the clutch hub, shell or bearing require replacement,
refer to

Clutch Hub and Shell Disassembly/Reassembly

this section.

Primary Chain

Replace the primary chain if severely worn or damaged.

Do not attempt to repair the chain. If the primary chain is
worn or damaged, check the engine sprocket and clutch shell
sprocket for wear or damage. Replace parts as required.

Adjust the primary chain as described in Chapter Three.

Clutch Hub and Shell
Disassembly/Reassembly

1. Remove the clutch plates from the clutch hub and shell
assembly, if they have not been previously removed. Refer
to

Clutch Disassembly on Motorcycle

in this section.

2. Remove the snap ring from the clutch hub groove (Fig-
ure 28).

CAUTION

If it is necessary to press or drive the clutch
hub out of the shell bearing, the bearing will
be damaged and must be replaced.

258

CHAPTER SIX

3. Remove the clutch hub from the clutch shell bearing.
4. Locate the snap ring securing the bearing in the clutch
shell. Remove the snap ring from the clutch shell groove.
5. Support the clutch shell in a press and press the bearing out
of the shell. The bearing must be removed through the front
side of the shell. The clutch shell is manufactured with a
shoulder on the rear (primary chain) side. Discard the bearing.
6. Discard worn or damaged parts. Clean reusable and new
parts, except bearings and snap rings, in a non-oil based
solvent and dry thoroughly.
7. Place the clutch shell into the press. Then align the bear-
ing with the clutch shell and press the bearing into the shell
until the bearing bottoms against the lower shoulder. When
pressing the bearing into the clutch shell, press only on the
outer bearing race. Installing the bearing by pressing on its
inner race will damage the bearing. Refer to

Service Meth-

ods

in Chapter One.

8. Install a new snap ring into the clutch shell groove.
Make sure the snap ring seats in the groove completely.
9. Install the clutch hub into the clutch shell bearing. If
pressing is required to install the clutch hub into the clutch
shell, be sure to support the bearing inner race.

10. Install a new clutch hub snap ring (Figure 28). Make
sure the snap ring seats in the clutch hub groove com-
pletely.
11. After completing assembly, hold the clutch hub and ro-
tate the clutch shell by hand. The shell should turn
smoothly with no roughness or binding. If the clutch shell
binds or turns roughly, the bearing may have been damaged
during reassembly. Correct before installation

Clutch Assembly

If the clutch assembly was not disassembled, refer to

Clutch Installation

in this section.

Before installing the clutch plates, count the number of

each plate. The set should include seven friction plates, five
drive plates and one spring plate.

Refer to Figure 29.

1. Soak all of the clutch plates in clean transmission oil for
approximately 5 minutes before installing them.
2. Align the tabs on a friction plate with the clutch shell
grooves and install the plate. Then align the inner teeth on

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)

259

CLUTCH

1. Snap ring
2. Snap ring
3. Guide
4. Bearing
5. Adjusting screw
6. Snap ring
7. Spring seat (flat)
8. Spring seat (U-shaped)
9. Diaphragm spring

10. Inner clutch spring seat
11. Pressure plate
12. Friction plates
13. Drive plates
14. Spring plate
15. Snap ring
16. Spacer
17. Clutch hub
18. Snap ring
19. Bearing
20. Clutch shell
21. Snap ring

a drive plate with the clutch hub grooves and install the
plate. Repeat until all of the clutch plates have been in-
stalled. Install the spring plate between the third and
fourth friction plates. The last plate installed must be a
friction plate.

NOTE

During clutch removal, if the spring com-
pressing tool was not removed from the dia-
phragm spring and pressure plate, proceed to
Step 4. If the spring compressing tool was re-
moved and the diaphragm spring was sepa-
rated from the pressure plate, continue with
Step 3.

3. Assemble the pressure plate and diaphragm spring as
follows:

a. Install the adjusting screw assembly (release plate,

snap ring, bearing and adjusting screw) into the pres-
sure plate. Install the release plate by aligning its tabs
with the slots in the pressure plate. Secure the release
plate by installing the retaining ring into the pressure
plate groove. Make sure the retaining ring seats in the
groove completely.

b. The diaphragm spring is concave. Install the dia-

phragm spring onto the pressure plate so the concave
side faces the pressure plate—the convex side must
face out.

c. Install the spring seat with its flat, larger outer diame-

ter side facing toward the diaphragm spring.

WARNING

A clutch spring compression tool (part No.
34761-84), is required to install the dia-
phragm spring (9,

Figure 29

). Severe per-

sonal injury from the diaphragm spring
flying out could occur if the special tool is
not used.

4. To install the diaphragm spring snap ring, use a clutch
spring compression tool to perform the following:

a. Install the clutch spring compression tool onto the

clutch assembly (Figure 30). Secure the spring
compression tool per the manufacturer’s instruc-
tions.

b. Position the spring compression tool against the dia-

phragm spring and thread the tool handle onto the
end of the forcing screw. Do not apply pressure
against the diaphragm spring at this time.

CAUTION

Turn the compression tool nut only the
amount required to compress the diaphragm
spring and install the snap ring. Excessive
compression of the diaphragm spring may
damage the clutch pressure plate.

c. Turn the compression tool nut clockwise to compress

the diaphragm spring.

d. Install the spring seat and snap ring into the groove in

the clutch hub prongs.

e. After making sure the snap ring is seated completely

in the clutch hub groove, slowly turn the compressing
tool handle counterclockwise while checking that the
clutch spring seat lip seats against the snap ring. After
all tension has been removed from the compressing
tool, remove it from the release plate.

5. Remove the release plate retaining ring. Then remove
the adjusting screw assembly.

260

CHAPTER SIX

Adjusting screw

Nut

Snap ring

Compression tool

Clutch Installation

1. Assemble the clutch assembly as described in this sec-
tion.
2. The engine sprocket, primary chain and clutch are in-
stalled as an assembly. Assemble the engine sprocket,
clutch and primary chain as shown in Figure 31.

CAUTION

The alternator rotor is mounted on the clutch
shell (

Figure 32

). Inspect the inside of the ro-

tor for small bolts, washers or other metal de-
bris picked up by the magnets. These metal
pieces damage the alternator stator assem-
bly.

3. Lift the primary drive assembly as a unit and slide the
engine sprocket and clutch into the primary chaincase (Fig-
ure 33).
4. Install the spacer and the clutch circlip (A, Figure 33)
and spacer behind the circlip.
5. Use a sprocket locking tool to prevent engine sprocket
rotation.

CAUTION

The engine sprocket is tightened to a high
torque specification. Be sure to hold the
sprocket securely when tightening the nut.

6. Apply of threadlock (Loctite 242 or equivalent) to the
engine sprocket nut threads and then install the engine
sprocket nut (B, Figure 33). Tighten the sprocket nut to
150-165 ft.-lb. (203-223 N•m).
7. Remove the sprocket locking tool.
8. Install the adjusting screw assembly (Figure 34) by
aligning the two tabs on the release plate perimeter with the
two recesses in the pressure plate.
9. Install a new snap ring (Figure 35).
10. Install the primary drive cover as described in this
chapter.
11. Adjust the primary chain (Chapter Three).
12. Refill the primary chain housing with the correct type
and quantity oil (Chapter Three).
13. Reconnect the negative battery cable (Chapter
Twelve).

CLUTCH CABLE

Replacement

Refer to Figure 1 and Figures 36-38.

1A. On 1986-1987 models, loosen the clutch cable jam nut
(A, Figure 36) and turn the adjuster (B) to provide maxi-
mum cable slack.
1B. On 1988-1990 models, slide the rubber boot off the
clutch in-line cable adjuster. Loosen the adjuster jam nut
(A, Figure 37) and turn the adjuster (B) to provide maxi-
mum cable slack.

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)

261

2. Remove the primary drive cover as described in this
chapter.
3. Pry the lockplate tabs away from the mounting screws
and remove the lockplate (A, Figure 38) and screws.
4. Remove the clutch release mechanism (B, Figure 38)
from the cover and disconnect the cable (C) from the ramp
and coupling. Hold the ramps together to prevent the balls
from falling out.
5. Turn the lower clutch cable fitting and unscrew it from
the primary drive cover.
6. At the clutch lever, remove the pivot pin circlip and re-
move the pivot pin.
7. Disengage the clutch lever from the handlebar bracket.
8. Disengage the cable end from the fitting in the clutch le-
ver.
9. Note the routing of the clutch cable and the position of
all cable clamps, then remove the clutch cable.
10. If necessary, remove the screw and anti-rattle spring
from the bottom of the clutch lever.
11. Inspect the bushing(s) in the control lever bracket. Re-
place if damaged or worn.
12. Inspect the pivot pin and replace if damaged or worn.
13. Inspect the cable retaining pin. Replace it if damaged
or worn.
14. Install the clutch cable by reversing the removal steps
while noting the following:

a. On 1988-1990 models, install a new O-ring on the

end of the lower cable housing fitting (Figure 39).

b. Install the lower cable housing fitting and tighten to

36-60 in.-lb. (4-7 N•m).

c. Connect the cable coupling to the outer ramp. Install

the clutch release mechanism and lockplate. Tighten
the screws securely and bend the lockplate tabs over
the screws to lock them.

d. Adjust the clutch (Chapter Three).

262

CHAPTER SIX

Table 1 CLUTCH SPECIFICATIONS

New

Service limit

in. (mm)

Friction plate thickness

0.1469-0.1531

0.130

(3.731-3.889)

(3.30)

Steel plate thickness

0.0609-0.0649

0.060

(1.5469-1.6485)

(1.524)

Warp

–

0.010
(0.25)

Table 2 CLUTCH TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Cable housing fitting

–

36-60

4-7

Engine sprocket nut*

150-165

–

203-223

Left footpeg

24-36

–

33-49

Primary drive chain cover

mounting screws

–

80-110

9-12

Shift lever pinch bolt

–

90-110

10-12

*Apply threadlock (Loctite 242 or equivalent).

PRIMARY DRIVE AND CLUTCH (1986-1990 MODELS)

263

CHAPTER SEVEN

PRIMARY DRIVE AND CLUTCH

(1991-2003 MODELS)

This chapter covers the primary drive cover, primary

drive, clutch assembly and clutch cable.

Table 1 and Table 2 are at the end of the chapter.

PRIMARY DRIVE COVER

(1991-1993 MODELS)

Refer to Figure 1.

Removal

1. Disconnect the negative battery cable (Chapter Twelve).
2. Remove the transmission oil drain plug (Figure 2) and
drain the transmission (Chapter Three).
3. Loosen the locknut (A, Figure 3) and turn the primary
chain adjuster screw (B) to loosen the chain.
4. Remove the clutch inspection cover (Figure 4).
5. Remove the spring and lockplate (Figure 5).
6. Turn the clutch adjusting screw clockwise (Figure 6) un-
til the nut can be removed, then remove the nut (Figure 7).
7. Remove the shift lever and left footpeg assembly (Fig-
ure 8) as described in Chapter Seventeen.
8. Remove the primary drive cover (Figure 9) and gasket.
The primary drive cover is retained by different length
screws (Figure 10). Create a drawing on cardboard in the

shape of the cover, then punch each screw through the card-
board at its location.
9. Remove the dowel pins (Figure 11), if necessary.
10. If necessary, remove the clutch mechanism as de-
scribed in this chapter.
11. If necessary, service the following components as de-
scribed in this chapter:

a. Clutch release mechanism.
b. Primary chain adjuster.
c. Shift shaft oil seal.

Installation

1. Clean the primary drive cover and engine crankcase gas-
ket surfaces and dry thoroughly.
2. Clean the magnetic drain plug and reinstall it into the
primary drive cover. Tighten the drain plug to 14-21 ft.-lb.
(19-28 N•m).
3. Assemble the clutch release mechanism and connect the
clutch cable as described in this chapter.
4. Install the dowel pins (Figure 11), if removed.
5. Using a new gasket, install the primary chain cover onto
the crankcase. Install the cover mounting screws into their
correct locations, as noted during removal, and tighten
them in a crisscross pattern to 80-110 in.-lb. (9-12 N•m).

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

265

CLUTCH RELEASE MECHANISM

(1991-1993 MODELS)

1. Screw
2. O-ring
3. Clutch inspection

cover

4. O-ring
5. Spring
6. Lockplate
7. Nut
8. Primary drive cover
9. Cable coupling

10. Outer ramp
11. Balls (3)
12. Inner ramp
13. Lockplate
14. Bolt
15. Clutch adjusting

screw assembly

16. Clutch cable

6. Thread the nut (Figure 7) onto the clutch adjusting
screw until the screw slot is accessible with a screwdriver.
Then align and install the hex portion of the nut into the
outer ramp recess. Turn the clutch adjusting screw (Figure
6) until the nut cannot be removed.

7. Adjust the clutch (Chapter Three). The spring and
lockplate shown in Figure 5 will be installed during the
clutch adjustment procedure.

8. Adjust the primary chain (Chapter Three).

9. Refill the transmission oil (Chapter Three).

10. Install the shift lever (Figure 8) and tighten the pinch
bolt to 80-110 in.-lb. (9-12 N•m).

266

CHAPTER SEVEN

PRIMARY DRIVE COVER

(1991-1993 MODELS)

1. 1/4-20 × 1 3/4 in. bolt with washers
2. 1/4-20 × 2 1/4 in. bolt with washers

LEFT FOOTREST SUPPORT

3. 5/15-18 × 3 1/2 in. bolt

PRIMARY DRIVE COVER

(1994-2003)

Refer to Figure 12.

Removal

1. Disconnect the negative battery cable (Chapter Twelve).
2. Remove the left side footrest assembly (Chapter Seven-
teen).
3. Drain the transmission oil (Chapter Three).
4. Loosen the locknut (A, Figure 3) and turn the primary
chain adjuster screw (B) to loosen the chain.
5. Slide the rubber boot off the clutch in-line cable ad-
juster.
6. Loosen the adjuster jam nut (A, Figure 13) and turn the
adjuster (B) to provide maximum cable slack.
7. Remove the clutch inspection cover.
8. Remove the quad ring (A, Figure 14).
9. Remove the spring and lockplate (B, Figure 14).
10. Turn the clutch adjusting screw (A, Figure 15) clock-
wise and release the ramp (B) and coupling (C). Turn the
clutch adjusting screw clockwise to move the ramp assem-
bly forward. Then unscrew the nut (D, Figure 15) from the
end of the adjusting screw and remove it.

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

267

CLUTCH RELEASE MECHANISM (1994-2003 MODELS)

1. Torx screw and

washer

2. Clutch spring

cover

3. Spring
4. Lockplate
5. Nut
6. Coupling

(1994-1996 models)

7. Outer ramp
8. Balls (3)
9. Coupling

(1997-2003 models)

10. Inner ramp
11. Quad ring
12. Snap ring
13. Primary drive cover
14. Clutch adjusting

screw assembly

15. Clutch cable
16. O-ring

11. Pivot the hook on the ramp to the rear of the cable end
coupling. Then disconnect and remove the clutch cable
from the slot in the coupling. Remove the coupling and
ramp assembly.
12A. On 883C and 1200C models, remove the bolt and
washer securing the rod assembly to the shift lever, then re-
move the shift lever.
12B. On models except 883C and 1200C models, remove
the clamp bolt and washer securing the shift lever to the
shift shaft, then remove the shift lever.
13. Unscrew the clutch cable housing fitting (Figure 16)
from the primary drive cover.
14. Remove the primary drive cover mounting bolts, then
remove the cover and gasket.
15. Remove the dowel pins, if necessary.
16. If necessary, remove the clutch mechanism as de-
scribed in this chapter.
17. If necessary, service the following components as de-
scribed in this chapter:

a. Clutch release mechanism.
b. Primary chain adjuster.
c. Shift shaft oil seal.

Installation

1. Clean the primary drive over and engine crankcase gas-
ket surfaces and dry thoroughly.
2. Using a new gasket, install the primary chain cover onto
the crankcase. Refer to Figure 17 and install the cover
mounting screws and tighten in a crisscross pattern to
80-110 in.-lb. (9-12 N•m).
3. Inspect the O-ring on the end of the cable housing fitting
(Figure 18). Replace if damaged.
4. Install the cable housing fitting and tighten to 36-60
in.-lb. (4-7 N•m).
5A. On 1994-1996 models, install the coupling onto the ca-
ble end with the rounded side facing out and the ramp con-
nector button facing in.
5B. On 1997-2003 models, install the coupling onto the ca-
ble end with the rounded side facing in and the ramp con-
nector button facing out. With the retaining side of the ramp
facing in; install the ramp hook around the coupling button.

Then rotate the assembly counterclockwise until the tang
on the inner ramp fits into the primary drive cover slot.

6. Thread the nut onto the clutch adjusting screw until the
slot in the end of the screw is accessible with a screwdriver.
Then align and install the hex portion on the nut into the

268

CHAPTER SEVEN

PRIMARY DRIVE COVER

(1994-2003 MODELS)

1. 1/4-20 × 1 3/4 in. bolt with washers
2. 1/4-20 × 2 1/4 in. bolt with washers

LEFT FOOTREST SUPPORT

3. 5/15-18 × 3 1/2 in. bolt

outer ramp recess. Turn the clutch adjusting screw counter-
clockwise until resistance is felt, then back off 1/4 turn.
7. Adjust the clutch (Chapter Three). The spring and
lockplate (B, Figure 14) will be installed during the clutch
adjustment procedure.
8. Adjust the primary chain (Chapter Three).
9. Refill the transmission oil (Chapter Three).
10A. On 883C and 1200C models, install the shift lever
and reconnect the rod assembly to the shift lever. Tighten
the rod bolt to 15in.-lb. (11 N•m).
10B. On all models except 883C and 1200C models, in-
stall the shift lever and tighten the clamp bolt to 80-110
in.-lb. (9-12 N•m).

11. Install the left side footrest (Chapter Seventeen).
12. Reconnect the negative battery cable (Chapter
Twelve).

CLUTCH RELEASE MECHANISM

(1991-1993)

Refer to Figure 1.

Removal

1. Remove the primary drive cover as described in this
chapter.
2. Pry the lockplate tabs (A, Figure 19) away from the
mounting screws and remove the lockplate and screws.
3. Remove the clutch release mechanism from the cover
and disconnect the cable (B, Figure 19) from the ramp and
coupling. Remove the clutch mechanism.

Inspection

1. Wash the clutch release mechanism in solvent and dry
thoroughly.
2. Inspect the balls and ramp sockets (Figure 20) for pit-
ting, severe wear or other damage.
3. Inspect the adjusting screw (Figure 21) for thread or
bearing damage.
4. Replace the lockplate if the tabs are weak or broken.
5. Replace severely worn or damaged parts as required.

Installation

1. Install the cable coupling onto the end of the clutch ca-
ble. Place the coupling in the ramp.
2. Apply grease to the ball and ramp surfaces (Figure 20)
and insert the balls into the ramp sockets.
3. Assemble the inner and outer ramps (C, Figure 19) and
install on the primary drive cover. Install the lockplate and
the ramp mounting screws. Tighten screws securely. Bend
the lockplate tabs over the screws to lock them in place.
4. Install the primary drive cover as described in this chap-
ter.
5. Adjust the clutch (Chapter Three).

CLUTCH RELEASE MECHANISM

(1994-2003 MODELS)

Refer to Figure 12.

Removal

1. Slide the rubber boot off the clutch in-line cable ad-
juster.
2. Loosen the adjuster jam nut (A, Figure 13) and turn the
adjuster (B) to provide maximum cable slack.

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

269

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 21