I was hopeful that the refusal of the Harley to go from neutral to first gear might be down to a clutch adjustment issue. Nope. I reset it several times but when I started it up it still wouldn’t do it. I’ve been working in fits and starts as I’ve been pretty consistently wasted with plague weakness. It’s not fun and it makes doing *anything* a Herculean task. I forced myself to do an hour, which turned into a few hours, on the bike. If it’s not clutch adjustment, maybe the clutch retaining ring wasn’t seated right, (the posts into which it fits got a bit bashed when I stripped it the first time). I had that spare complete clutch basket, and I know what I’m doing this time, so I thought I’d just whip my clutch off, move the clutch plates and such to the new clutch, then refit it. That all went quite smoothly. I rebuilt the new clutch, put it in the chain with the other piece that you fit as a unit.
It wouldn’t go on. I spent a fair while wondering what the hell I’d done wrong this time that I didn’t previously. I managed to wedge it back on in the end but the connecting chain was straining taut. It’s supposed to have an inch of play that you take out with an adjuster. I’m guessing the clutch is from a later model and is slightly bigger. Too big. Then I had the problem of getting the two pieces and the taut chain off as a unit. The stator is behind the front cover, so the magnets make it tough to get off normally. Like that is seemed almost impossible. I tried several levers to prize it off, but I was scared of damaging the mating surface for the gasket. In the end I squeezed a claw hammer in to give me leverage. I got the clutch off but in doing so snapped a little lever I hadn’t realised I was pressing against. A small part of the gear selection mechanism called a detent arm.
And then the fun really starts. It’s a small, cast, arm. So, difficult to weld. Harley don’t make the part any more. I found one place in Japan that would make the part to order. One. On the whole of the internet. They charged me £36, which was fair. Then emailed me back two days later saying the part was no longer in production and refunded me. I scoured the internet, not one single source for a new part anywhere. I found other posts asking different forums where they could source it, without any good reply. I tried Harley breakers. Nothing. The single solitary source for it was a rip-off American breaker on eBay. I can either wait for someone to kill their bike and strip it down to sell for bits, or buy off the rip-off. £173! Gutted. On principle. And it’s my own stupid fault in the first place. Doubly aggrieving.
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