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Discussion Starter #1
Hello, fellow streeters,
Recently I have had my clutch replaced as it was beginning to slip under power in 4th and 5th gears. I was going to replace it myself, however, I was unsure if any of the performance parts would fit as I was looking to upgrade. So I took my HD Street XG500 to the local dealer and had them install a Barnett kevlar clutch kit (PN 303-30-10045). I expect that I will be replacing clutches quite frequently as I have a history of being quite heavy on them and have already bought a second-hand complete clutch basket.

After the dealership technician installed the Barnett component I asked him for some pointers, he mentioned that there was an HD special tool which aids in removal and installation of the clutch basket. It seems that there may be many different HD special tools that aid in this maintenance job on Harley-Davidson's, but I could not find one that specifically suits the HD Street XG500.

Here’s what I have found so far:
HD-51505 eBay (Harley-Davidson clutch locking tool)
PN 283 850 Dennis Kirk (Clutch lock up tool CLT-100)
PN 282 596 Dennis Kirk (Barnett - Scorpion Clutch lock up plates 638 30 80001)

Does anyone on here have any idea what HD Special tool the technician was referring too?

Thanks in advance Steve.
 

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Discussion Starter #3
So, how does that Barnett clutch feel? Did it make a difference?
I have not really ridden much since installation distance wise, however, differences that I have noticed to date is that the clutch is similar to a sports bike. For example, the lever is slightly heavier, the take-up is more defined either engaged or disengaged, and gear selection is more defined.

So far I am enjoying the new feel and this is a change for the good, as I thought the standard clutch take-up was mushy and gear selection was inferior.

:):):):)
 

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Hello, fellow streeters,
Recently I have had my clutch replaced as it was beginning to slip under power in 4th and 5th gears. I was going to replace it myself, however, I was unsure if any of the performance parts would fit as I was looking to upgrade. So I took my HD Street XG500 to the local dealer and had them install a Barnett kevlar clutch kit (PN 303-30-10045). I expect that I will be replacing clutches quite frequently as I have a history of being quite heavy on them and have already bought a second-hand complete clutch basket.

After the dealership technician installed the Barnett component I asked him for some pointers, he mentioned that there was an HD special tool which aids in removal and installation of the clutch basket. It seems that there may be many different HD special tools that aid in this maintenance job on Harley-Davidson's, but I could not find one that specifically suits the HD Street XG500.

Here’s what I have found so far:
HD-51505 eBay (Harley-Davidson clutch locking tool)
PN 283 850 Dennis Kirk (Clutch lock up tool CLT-100)
PN 282 596 Dennis Kirk (Barnett - Scorpion Clutch lock up plates 638 30 80001)

Does anyone on here have any idea what HD Special tool the technician was referring too?

Thanks in advance Steve.

The clutch Locking tool is HD 51505 and the crank locking tool is HD-51281
Clutch assembly nut torque is 130-136 FT lbs
Clutch lifter plate screws 71-88 Ft lbs
Install Trust washer beveled side toward engine.


I only mention this for educational reasons . The locking tool keeps things from turning so you can get it apart and put it back together. There are other ways but do not use a steel block or wedge
 

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Discussion Starter #6
@smitty901,
Thanks for the information (I watched it in full and the following video about maintenance) while the crank locking tool (HD-51281) seems intuitive as its job is to lock up the engine by binding that one sprocket/gear.

The other tool the clutch locking one (HD 51505) is put into service in such a way that I could not register what its function was or how it operated?





The tool obviously, holds the clutch basket in place, but is that to take the weight off the retention nut or to aid in calibrating the correct tension of 130-136 FT lbs or does it do something else?

Thanks again for your help.
 

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Discussion Starter #8
How many miles do you have on your bike if you need the clutch replaced already?
I bought the Street 500 second hand, and in Australia these bikes are apporoved for learner riders. I was expecting to replace the clutch as many learner riders take-off by bounching the engine off the rev-limiter and feathering the clutch. Which leads to premature friction disk wear, I guess they learn how to do it differently once they pay for a replacement.

The bike had only 5,600kms on the odometer and I must have added another 5,000 kms before I noticed some slipping, as I mentioned above, only in 4th and 5th gears.

I have the old clutch pack and most of the metal discs and friction discs are still in a servicable condition though.
 
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