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Pull primary cover and then pull primary chain adjuster and compensator and clutch and chain out and then remove six metric bolts and remove clutch pressure plate and discs and then replace hub and bearing assembly and replace clutch disc and pressure plate etc as you took them apart. Might not cost that much more to simply buy a whole new clutch assembly and have it all new. You will need a bar to lock the primary and compensator together when you loosen and when you tighten the retaining fasteners.
Tighten compensating sprocket bolt to 100 ft-lbs (135.7 Nm) and then reverse the drive locking tool and loosen the bolt one full turn and then reverse the locking tool again and tighten the bolt to a final torque of 140 ft-lbs (190.0 Nm). Install the locking tool again and tighten the clutch hub mainshaft nut to 70-80 ft-lbs (94.9-108.5 Nm).
After the compensator and clutch fasteners have been torqued Install the primary chain tensioner and tighten the fasteners to 15-19 ft-lbs (20.3-25.8 Nm).
It sounds like you have a problem with your clutch assembly. Unless you have the tools and ability to rebuild it yourself then I would advise taking it to a dealer.If you decide to try the repair yourself respond to this answer and I will send you a link with info
To adjust the clutch, follow the clutch cable down to the frame front downtubes and find the cable adjuster. It's usually covered with a rubber bellows. Slide the bellows up or down exposing the adjuster. Loosen the lock nut and turn the cable adjuster in all the way getting as much slack in the cable as possible.
Then take the derby cover off the primary. In the center of the clutch assembly, you'll see an adjuster screw and a lock nut. Loosen the lock nut. Turn the adjuster screw inward until you feel a resistance. DO NOT FORCE THE SCREW OR YOU'LL BREAK YOUR INNER CLUTCH HUB. If you need to, back the screw out and turn it back in just till you feel the resistance several times to get the feel of it. Once you feel the resistance, back the screw off 1/2 turn and lock the lock nut down.
Then, go back to the cable adjuster and turn the adjuster barrel out until you have about 1/8 inch of freeplay in the cable. Tighten the lock nut and replace the rubber bellows. Replace the derby cover.
To adjust the clutch on your ultra, first find the clutch cable and follow it down until you find the rubber bellows cover over the clutch cable adjuster. Move the cover out of the way and loosen the locknut. Turn the cable adjuster inward to get as much slack as possible in the cable.
Now, remove the derby cover. In the center of the clutch assembly, you'll see an adjuster screw and locknut. Loosen the locknut. Turn the center screw inwards until you feel a resistance. Do not force the screw. Turn it inwards until you feel the resistance. Then back it back out 1/2 turn and lock the locknut. Replace the derby cover.
Go back to the cable adjuster and adjust it outwards until you have an 1/8" freeplay at the hand lever. Lock the locknut, replace the cover. You may have to tweak the adjuster just bit to get the engage point exactly where you want it.
you could use a blind hole bearing remover w/slide hammer these bearing are suppose to be tight and straight.if they are removed and installed wrong you could ruin the hub. Harley switched to sealed wheel bearings in 2000 earlier models were tappered bearings.
Disconnect battery , remove the outer primary case, pull back the lock
tab on the starter jackshaft, unbolt the retainer screw, then remove
the two starter bolts from the right side, sometimes you need to loosen
the oil tank mounts to get at these, slip the starter and coupler out
as a unit, replace the coupler and jackshaft the same way they came out
when the new starter goes in, install bolts , retighten the jackshaft
bolt and bend over the retainer, install and fill primary case, connect
thats it buddy
Yes, The first thing you do is disconnect the battery ,,,Harley says to pr3vent accidental starts, but if you dont, your going to short something out..... You are going to have to remove the outer primary to get to the jackshaft. Disassemble and pull the jackshaft then you can unbolt and remove the starter ,,,,,