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Discussion starter · #21 · (Edited)
Re: 78 iron head stuck in 4th gear thinking of buying

thanks for the info! I found one on ebay for 10.99 + shipping..

"Clutch Puller Tool for 1971 to earley 84 Harley Davidson Sportster. This tool is made out of 1" x 1" x 1/8" wall steel tubing. This tool is for releasing the presssure of the clutch springs, so you can take the clutch apart to replace plates,ect. I will include instructions for use with tool. Thank you for looking."

price seems reasonable and I'm sure I will use it again sometime down the road so I ordered it...
 

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#22 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Thats exactly what you need. Hopefuly you'll only need to use it once.
 
Discussion starter · #23 ·
Re: 78 iron head stuck in 4th gear thinking of buying

since I have to wait for it to come in I ordered a primary lock tool to lock up the chain so i can take off the comp nut... guess i could have made one out of a plastic cutting board or used a rag or 2 * 4 but what the hell.... Never go wrong buying a new tool as far as I am concerned...
 

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#25 ·
Re: 78 iron head stuck in 4th gear thinking of buying

What sounds like what happend is the shifter rod is out of the ratchet pawl, if you try and jam the shiffter to hard, this will happen, so when ya pull the trans and watch out for all the output shaft bearings, they will fall out, use vasalean or grease to hold them in, you will see two steel flaps on ether side of the shifter shaft ball end, one might be bent, just adjust it back to the up right position and reinstall the trans and you should be good to go.....................Roach.
 
#27 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Thats a good deal and should be an easy fix. You can use a peice of flat bar jambed between the clutch gear a primary sproket to get the nut off.
 
Discussion starter · #28 · (Edited)
Re: 78 iron head stuck in 4th gear thinking of buying

Splines on shifter shaft were worn some so I ordered a new one from Debrix.com. They were not that bad and probably would have worked fine, but I figure since I have to tear it apart I should just replace it...
 

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Discussion starter · #29 ·
Re: 78 iron head stuck in 4th gear thinking of buying

I used the clutch puller to compress, remove the 6 nuts and then ease out the spring. Gotta work late tonight on my day job so thats all I can get done today...

quick question: do I have to remove the retaining ring and plates or can I just remove the big nut and take it off together.

thanks!
 

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#30 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Minght as well remove the retainer and plates, you will have to have them a seperated to put it back together.
 
Discussion starter · #32 ·
Re: 78 iron head stuck in 4th gear thinking of buying

PONY said:
Are those spacers on the clutch studs that I see in the pic.
Click to expand...
yep all 6 have a spacer?? Is that good or bad news for me??
 
#33 ·
Re: 78 iron head stuck in 4th gear thinking of buying

its good that you have the sparcers!
 
#34 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Yes thats good. The earlier setup without the spacers had to have the pressure plate gap set with a ruler. If you got any of the studs adjustment off it made the clutch slip, drag or engage poorly. Use new locknuts and Don't overtighten and snap off the studs.
 
#35 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Yep, thats why I just love Ironhead clutches!!! ;)

......................Roach.
 
Discussion starter · #36 · (Edited)
Re: 78 iron head stuck in 4th gear thinking of buying

cool!, I got the front sprocket nut off, took a long breaker bar but was not too bad. little plastic lock up tool worked great. I don't have a socket big enough for the clutch hub so I'll have to buy one tommorow. Clutch nut is NORMAL thread on a 78 sportser! Left to loosen....

thanks for the help I'll post more pics as I go...
 
Discussion starter · #37 ·
Re: 78 iron head stuck in 4th gear thinking of buying

I pulled the retainer ring and plates. first metal plate is cracked and the 3rd metal plate is cracked, did not go through the rest of them... guess i need to buy new plates while I'm at it.... hope to take off the clutch nut and get to the transmission this weekend...
 

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#38 ·
Re: 78 iron head stuck in 4th gear thinking of buying

Owch!!! Now before you pull the trans, look at the shifter shaft, is it floped down or is it still where its supposed to be in side?? you should beable to look down the legth of it .................Roach.
 
Discussion starter · #39 · (Edited)
Re: 78 iron head stuck in 4th gear thinking of buying

I went ahead and ordered the following from debrix.com:

8pcs Steel Clutch Drive Plates Kit for 1971-E1984 Harley XL Sportster
SKU : 73161-M1 1 $35.99 USD
1543110 Barnett Friction Plate Set for 1971-1984 Harley XL Sportster
SKU : 18-3122 $54.99 USD
 
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little d
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