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Clutch Plate Replacement

4082 Views 21 Replies 12 Participants Last post by  Bob777
My Challenger clutch slips under heavy load at times. I'd like to put the Barnett clutch kit with the extra plate and upgraded springs in.

My question is, can I do this without actually removing the clutch basket from the bike? The service manual lists a "staking nut" (#4 in diagram below from the Challenger manual) which is torqued to 125 lb-ft which must be removed to fully take the clutch basket out, and of course this requires a special procedure for locking the crankshaft.

On the TS111 it looks like a very simple job (see this post) to change the friction plates and springs without major disassembly. Looks like you can take the pressure plate off without touching this "staking nut". Is the PowerPlus the same way?

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My buddy had his replaced under warranty. His cable was frayed and not releasing completely. It was only a few months old at the time. Another buddy just said his is slipping after our ride on Saturday. He's contacting the dealer about warranty. If mine starts to slip I think I'll get a Barnett.
I just got my bike serviced and after that my clutch started slipping about 4 weeks after that service. After adjusting freeplay, it was still slipping. They just pulled the clutch apart and found it was burnt up. Only 13K miles. I'm upset that the bike got serviced, and I found that there was no free play in the clutch lever at all the entire time I have been riding the bike. It wasn't set up properly and now I have to pay the price to get it fixed as Indian would not warranty it as it came setup that way from the factory.
Ask them to check the cable for fraying. I've heard of others beside my friend that had that issue.
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Yeah, That's what I think did it, The dealer is going to eat the labor to install the new clutch since they are the only ones that have touched the bike, but I have to buy the parts. Just ordered the Barnett next day air shipment right to the shop so I can get rolling again by the weekend.
Let us know how you like the Barnett, it will be interesting to hear if there is any noticeable difference.
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