Harley Davidson Sportster (1959 to 1969). Service manual - page 9
ASSEMBLING CLUTCH RELEASE MECHANISM (Fig. 4B-6)
Assembly is essentially the reverse order of
disassembly. Dip ends of release rods in oil. Insert clutch release rod
- left (9) in clutch gear end. Slip release rods (12, 11 and 10) in
place from sprocket side in order shown (see Fig. 4B-6). Install clutch
parts (10-1, Fig. 4B-8) as described under, "Assembling Clutch'
Assemble clutch release lever and worm (4), spring (5), cover (8),
adjusting screw (7) and lock nut (6). Check lever and worm action by
moving lever back and forth. Engage cable (3) end with fingers of lever
and install sprocket cover (2) with bolts (1). Inject "Grease-All"
grease through fitting to lubricate worm.
Check the operation of the release lever to be sure lever returns to
stop pin, when clutch hand lever is released. A sticking worm or clutch
control cable causes lever to stop short of pin, thus reducing effective
clutch release rod travel, causing clutch to slip.
Install footrest, exhaust pipe, muffler and starter crank. Adjust clutch
release mechanism as described under "Adjusting Clutch Release
Mechanism.”
DISASSEMBLING CLUTCH
Remove front chain cover and clutch cover as described under "Adjusting
Clutch Spring Tension."
See Fig. 4B-8 and proceed as follows. Remove the three 7/16 in. hex-head
nuts (5), and three 1/2 in. hex-head nuts (6). Remove spring-tension
adjusting plate (7), springs (8), spring cups (9), releasing disc (10),
seven clutch friction-drive plates (11), seven clutch steel-driven
plates (12) and backing plate (13). All plates may be easily removed by
tipping engine, or removed individually, using a piece of wire with a
hook formed on one end.
See Fig. 4B-9. Remove front chain adjuster brace and three front chain
adjuster cap screws (1). This will leave the chain adjuster (2) loose
behind the front chain. Install Sprocket Locking Link Tool (3), Part No.
97200-55, between engine sprocket teeth and clutch sprocket teeth to
prevent clutch and compensating sprocket from turning.
Insert Clutch Lock Plate (4), Part No. 97175-55,
between clutch hub (5) and sprocket (6) as shown in Fig. 4B-9. Bend ears
of lock washer (15, Fig. 4B-8)away from hub nut and remove release rod -
left (9, Fig. 4B-6). Remove clutch hub nut (14 or 14A, Fig. 4B-8) using
Wrench, Part No. 94647-52, (7, Fig. 4B-9).
Pry hub nut lock washer from hub and discard. Pry oil seal (27, Fig.
4B-8) from clutch gear end with screw driver or release rod end that has
been wiped dry. Install clutch Hub Puller (1), Part No. 95960-52, and
remove clutch hub (16) from splines of clutch gear as shown in Fig.
4B-10. Remove O-ring (18) from groove in clutch gear (30) (1967 XLH
only).
Using Compensating Sprocket Shaft Wrench (2), Part No. 94557-55, remove
shaft nut as shown in Fig. 4B-10,