1. Prep Work:
- Disconnect the battery to avoid electrical issues during the repair.
- Lift the motorcycle securely using a motorcycle lift or jack stands to access the transmission and primary drive components.
- Remove the primary cover by unscrewing the bolts that hold it in place.
2. Remove the Clutch Assembly:
- Remove the clutch springs using a specialty clutch spring tool.
- Slide the pressure plate and clutch plates off the clutch hub assembly.
3. Access the Throwout Bearing:
- Remove the clutch basket by unbolting it from the transmission.
- Pull the clutch shaft out of the transmission. This will expose the throwout bearing and race assembly.
4. Remove the Old Bearing:
- Use snap ring pliers to carefully remove the snap rings that hold the bearing in place.
- Slide the throwout bearing off the shaft. Inspect the race assembly for any damage or excessive wear.
5. Install the New Bearing:
- Lightly coat the new bearing's surface with high-temperature grease.
- Slide the new bearing onto the shaft, aligning it with the race assembly.
- Secure the bearing using new snap rings.
6. Reassemble the Clutch:
- Reinstall the clutch basket, pressure plate, and clutch plates. Ensure that the clutch plates are facing in the correct direction as specified in your motorcycle's manual.
- Install the clutch springs and tighten them evenly using the clutch spring tool.
7. Reinstall the Primary Cover:
- Reposition and secure the primary cover back onto the transmission. Tighten the bolts evenly to avoid warping the cover.
8. Test and Finish:
- Connect the battery and test the clutch function by engaging and disengaging the gears. Ensure smooth operation.
- Lower the motorcycle from the lift or jack stands and take it for a short test ride to ensure proper functionality.
Remember that replacing a Harley Davidson throwout bearing can be a complex task, and it's recommended to follow your specific motorcycle's service manual for accurate instructions. If you're not confident in your mechanical abilities, it's best to have the work done by a certified motorcycle mechanic.
