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post #1 of 3 (permalink) Old 05-28-2016, 06:49 AM Thread Starter
Join Date: May 2013
Location: Oldham Co. Kentucky
Posts: 4
Clutch/Throwout bearing issue

Have had a chattering when taking off in first gear for long time. 35,000 miles on 2011 RG Ultra 103. Usually goes away after changing primary oil, adjusting clutch, and free play. Saw this being mentioned by other Harley riders in different forums so thought it was just symptomatic or the way I engage when taking off.
I do most of my own servicing, but has also happened when Harley serviced. Harley techs have never mentioned this when they have serviced bike. Oil is changed and adjustments made frequently and regularly.The problem does go away for a while each time it is serviced and returns after riding some (not a lot) of miles.
Last time rode the clutch lever would come all the way back to grip but clutch wasn't disengaging. Figured broken or stretched cable. Have seen that before.
Simple fix - not! In order to get the cable out have to remove clutch release cover. First take off heat shields on rear exhaust (Rush True Duals), then loosen exhaust at cylinder head, remove bolt holding pipe to frame, take off right bag, loosen muffler bolts, drop pipe, remove cover.
Oil drained from cover so it had not ran dry. Cable not stretched at all, but the quarter sized throwout bearing had disintegrated, not worn or loose, disintegrated. Carrier holding roller bearings had separated, roller bearings lying lose in bottom of cover.
First Harley dealer said would have to order bearing, second said had lot in stock. Sounds like this may be a common issue.
Parts: Gasket - $5.23, Bearing $7.05, Thrust races $6.60.
Drained transmission and refilled with oil. Could get into long discussion regarding oils, but will wait.
Put back together - easier than taking apart! Drained primary and refilled, adjusted clutch plates, adjust free-play.
Rode 75 miles, no chatter when engaging or change in free-play, no chatter when hold front brake and rev slightly. Will report again after some serious miles.
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post #2 of 3 (permalink) Old 05-28-2016, 08:08 AM
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Join Date: Apr 2016
Location: Ontario Canada
Posts: 280
I had the same issue on a 2009.

The previous owner had the bike serviced regularly by a Dealer in Texas. Instead of inspecting issues... like Neutral Rattle etc...

They simply kept tightening the clutch pushrod. That crushed the bearing. I would never have known had I not been switching out cables when I changed to WO757 Bars.

BTW... no need to loosen Header pipe.. with ball jointed allen keys you can get the plate off. Some even lay the bike on the left side as to not drain the fluid...

In Canada the gasket was $5.75 and I got a complete flywheel with bearing from my local indy for $5.00.

Ironically though... I ended up doing the job again and taking the bearing off the flywheel and putting it back on the original.

That helped with the Rattles etc. Then (because it was a 103) I backed off the basket nut 1 full turn and adjusted the pull on the cable head at the lever to about 1/16th-1/8th"... Then filled the Primary to just below the derby cover holes...

That bike ran strong, quiet, neutral was always easy to find...

Now I have this Hydraulic clutch assembly and it seems you have the luck of the draw.... Some make no noise... some rattle like marbles in a can... Funny....

You don't hear about all these mystery noises from "After Market" transmissions... like Baker or S&S.... Hmmm!!!

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post #3 of 3 (permalink) Old 06-05-2016, 09:33 PM Thread Starter
Join Date: May 2013
Location: Oldham Co. Kentucky
Posts: 4
Followup to previous post. Rode 780 miles through eastern Kentucky and Tennessee mountains. Ride consisted of interstate highways, mountains, and twisting/turning narrow back roads. No issues with transmission, clutch or throwout bearing. Chatter did not return.
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clutch , throwout bearing

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