Popular Post Goat Posted November 22, 2022 Author Popular Post Posted November 22, 2022 While this was this far apart, i thought i'd replace the base gaskets too. Removed the barrels, and tooke pistons out for blasting too. The heads looked disgusting. Ther earlier XLH900s were meant to have silver painted heads. I dont like them. So sandblast and a matty black was in order. Starting to reassemble with new gaskets: After blasting the heads, and what a shit of a job that was. I didn't want to do the barrels. So a quick hone and wacked them back on. Bike started like a champ after being sitting for 8 months. However, it was leaking oil from the base gaskets at orders of magnitude more than before. Fuck it. Back to square 1. Could see it pumping out like an artery! This is after a brakecleen and a wipedown! Was pooling before my eyes. The fact this had wet-sumped while sitting probably doesn't help. But I suspect I need to apply a lot more generous amounts of sealer to the base gaskets! It could also be because the oil pump is incorrectly timed.... (I know, wat?) But they use crank pressure to scavenge oil, and there is a rotary valve, so if that's not open when the crank is under pressure then it cant push the oil out. This would have been like this before my tenure. Could explain why it was also leaking before. Ah well, at least its easy to strip down. Also, replaced the clutch with new everything. Still need Arnie amounts of strength to pull the lever. Only thing I haven't replaced is the cable. So will try that (though it seems to move freely...) 9 1 Quote
Popular Post Goat Posted November 22, 2022 Author Popular Post Posted November 22, 2022 Not all doom and gloom on the freedom front though, Been fixing up this 83 for my Dad. Imported from the states many years ago. Gave it an all round freshen up and got it complied on Saturday. Runs mint, has a soft clutch, and doesn't leak oil! Shout out to Richard and Hayhole for the sweet stickers on the tank! You guys are the best: 16 2 Quote
Popular Post Goat Posted November 22, 2022 Author Popular Post Posted November 22, 2022 A bit of tuesday night bike night motivation. Got the dudes in there helping, hoping the freedom will catch and i'll have someone to do a chopper build with! Took top end off. So simple to work on. There is some very uneven mating surfaces at the base of the barrels... between 0.5 and 1mm out of flat. No wonder it was leaking. I think there was so much oil cos it was wet sumping, but still, would be weeping forever. Applied excessive gasket goo to hope it seals. Its nice grey stuff, not red. So can hardly notice it. Will cut back the eccess (no pics with pots back on) will put heads on later this week. Hopefully get it running again in the weekend. 16 Quote
Popular Post Goat Posted February 9, 2023 Author Popular Post Posted February 9, 2023 Oil leaks fixed! Just got a clean sheet wof for nats. Indicator broke off with metal fatigue on the way back. Excellent. 16 1 3 Quote
Goat Posted February 11, 2023 Author Posted February 11, 2023 Final chapter of the brutally hard clutch saga. I replaced the clutch cable as this was the last part of the clutch system i haven't replaced. Still hard as fuck. Yay. I have replaced: Clutch basket Clutch plates Clutch release mechanism Clutch springs Clutch spring spacers Cable Lever and bracket Still brutally stiff. I don't know. Looks exactly the same as my other one, which has a clutch as soft as butter. I don't know. What turds. 2 Quote
tortron Posted February 11, 2023 Posted February 11, 2023 Maybe you should lap in every moving part together. Probably a case of everything being on thrle bad side of inspec Or eat your weetbix ya girls blouse 1 Quote
Kimjon Posted February 13, 2023 Posted February 13, 2023 If its the same as a dry clutch, double check the witness marks in the clutch inner and outer. They go together a certain way. Its possible to assemble them the wrong way. 1 Quote
Goat Posted February 13, 2023 Author Posted February 13, 2023 Tis a wet clutch. Ima try tomorrow to switch the other release mechanism in now its got the new cable. @Lord Gruntfuttock, is your clutch miserably hard? Quote
Lord Gruntfuttock Posted February 13, 2023 Posted February 13, 2023 Nah it's pretty sweet for one of these. Will see how the new springs go in a week or so... Does the 77 have the 3 ball rotating release ramp? There's really not much to go wrong if the balls and ramp are right. I think most times it's the cable. I did shorten mine a lot so that prob helps... 1 Quote
Lord Gruntfuttock Posted February 13, 2023 Posted February 13, 2023 From the XL forum (my go-to) "When you pull in the clutch lever: The lever moves. The cable moves in the housing. The release ramp rotates. The 2 large coil springs compress. (This releases pressure on the plates and now they are free to slide around disengaged.) That is all that happens. Clutch plates are not involved at all. The ramp is not going to bind This leaves the cable as the cause of your problems with the lever being hard to pull in." 1 Quote
SOHC Posted February 13, 2023 Posted February 13, 2023 I rember you had to set the adjustment so when the 3 balls run up the ramps the cabel arm stops at 90 degrees 2 Quote
governorsam Posted February 13, 2023 Posted February 13, 2023 3 balls deep before adjustment. back off cable and adjusters. go from there 1 Quote
Goat Posted February 13, 2023 Author Posted February 13, 2023 Yeah, has the 3 ball ramp. Ive made sure the balls are deep and there is still plenty of pull before is start to adjust it, It has perfect amount of throw, and releases properly. But its just still so firm. Could be the new cable is a dud, the old one was pretty stiff, but clutch feels exactly the same. haha. My ramps look steep, the replacement mechanism i got (v-twin cheapie) has way shallower ramps, but it still feels the same? I don't know. Quote
Eatsrootsleaves Posted September 11, 2023 Posted September 11, 2023 Nice Ironhead did you solve the clutch issue ?, I can see that over the years its become a XLCH that started life as a XLH , and that clutch pressure plate is off an early model ? with the extra holes where small studs would of been , so you need to check as their are three different spacer sleeve sizes for ironheads , make sure you have the correct length spacer tubes ? are the early pressure plates the same thickness? because seeing that early pressure plate on the 77 and reading about your clutch woes something is not adding up here , I have a 74 xlh with a mustang tank like you brought your bike with , their not very common , quite hard to get , enjoyed your blog cheers 1 Quote
anglia4 Posted September 12, 2023 Posted September 12, 2023 Just to chuck another idea at it, it wouldn't have an aftermarket clutch lever or something silly like that, which might have a different leverage ratio to what it should? Quote
h4nd Posted September 15, 2023 Posted September 15, 2023 Extending ^ this idea: how original do you want to keep it? Check this: https://www.billetproofdesign.com/hydro-clutch-hydraulic-clutch-assembly-kit-fits-1971-1984-harley-davidson-sportster-xl-with-ironhead-made-in-usa/ Quote
Eatsrootsleaves Posted September 17, 2023 Posted September 17, 2023 On 11/02/2023 at 13:28, Goat said: Final chapter of the brutally hard clutch saga. I replaced the clutch cable as this was the last part of the clutch system i haven't replaced. Still hard as fuck. Yay. I have replaced: Clutch basket Clutch plates Clutch release mechanism Clutch springs Clutch spring spacers Cable Lever and bracket Still brutally stiff. I don't know. Looks exactly the same as my other one, which has a clutch as soft as butter. I don't know. What turds. I remember installing a new main spring once the two one sits inside the other , and that new spring was too strong mad the clutch hard to pull in ! Quote
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