Kit Number
This kit is designed to fit 1999 and later Evolution 1340 and Twin Cam-equipped models with Original Equipment (OE) clutch (derby) cover (Except 2003 anniversary models).
Additional Parts Required
Proper installation of this kit requires the separate purchase of a new clutch cover seal. See the appropriate parts catalog for the part number.
If an accessory clutch cover is installed, it may not provide adequate clearance over the new clutch plate. A 6.2 mm (¼ in) spacer kit (Part No. 37000123) is available for separate purchase.
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
Kit Contents
See Figure 7 and Table 1.
Block or jack vehicle under frame in a way that the vehicle will not fall over. Failure to properly block and/or raise the vehicle could result in death or serious injury. (00462c)
1. Position the motorcycle upright on a stand or jack.
2. See the service manual. Remove the clutch cover.
3. Use the template included in the kit to check the clearance of the clutch cover. If clearance is not adequate, purchase spacer kit (Kit Part No. 37000123) separately.
a. Cut out the template included in this kit.
b. See Figure 1. Align bolt-mark on template to the top bolt hole in the clutch (derby) cover and, then position the lower side of template between the bottom two holes in the cover.
c. Verify that the variable pressure clutch has adequate running clearance. If it does not, separate purchase and installation of spacer kit (Kit Part No. 37000123) is required.
4. See the service manual and Figure 2. Add freeplay to the clutch cable until the adjuster is fully collapsed.
a. Slide rubber boot (1) off cable adjuster.
b. Hold cable adjuster (2) and loosen jamnut (3).
c. Turn cable adjuster until the clutch adjuster is fully collapsed.
For 2004 and later Japanese models with helical gear transmissions, back out the adjusting screw at least 3/4 of a turn.
2Clutch cover
Figure 1. Check Clutch Cover Clearance
1Rubber boot
2Cable adjuster
4Cable end
Figure 2. Clutch Cable Adjuster
5. Adjust the clutch adjuster screw (2) with the stock retainer spring in place.
a. Turn the screw in until it gently bottoms out.
b. Turn the screw out 1/2 to 1 turn.
6. Loosen 6 screws (3) a little at a time and carefully remove the diaphragm spring retainer (4).
2Clutch adjuster screw
3Screw (6)
4Diaphragm spring retainer
Figure 3. Clutch Adjuster Screw and Diaphragm Spring Retainer
7. See Figure 7. Bend the tabs of the base plate (2) slightly to match the angle of diaphragm spring.
8. See Figure 4. Starting with the widest tab on the baseplate, insert it inside the diaphragm spring. Check to make sure that it is fully seated.
9. See Figure 5. Starting with one of the bottom levers, install the variable pressure clutch.
Figure 4. Install Base Plate
Figure 5. Install Variable Pressure Clutch
10. See Figure 5 and Figure 7. Secure the variable clutch.
a. Start installing each of the bolts (3) and washers (4) included in the kit.
b. Tighten each bolt to just snug.
c. Check that the diaphragm spring is in the proper position.
d. In an alternating pattern, tighten each bolt to 10.2–12.4 N·m (90–110 in-lbs).
11. See the service manual and Figure 6. Adjust the clutch cable (1) and allow at least 3.1 mm (⅛ in) of free play (4).
If an accessory clutch cover is installed, it may not provide adequate clearance over the new clutch plate. A 6.2 mm (¼ in) spacer kit (Part No. 37000123) is available for separate purchase.
If installing clutch cover seal (Part No. 25416-99C) it will be necessary to cut out the solid center of the seal in order to provide adequate clearance for the variable pressure clutch.
12. Install clutch cover, seal and screws. Alternately tighten screws to 9.5–12.2 N·m (84–108 in-lbs).
1Clutch cable
2Cable ferrule
3Clutch lever bracket
4Free play: 1/8 in. (3.1 mm)
Figure 6. Clutch Cable Free Play
Figure 7. Service Parts: Variable Pressure Clutch
Table 1. Service Parts
Description (Quantity)
Part Number
Clutch plate
Not Sold Separately
Wear ring, clutch
Bolt (6)
Not Sold Separately
Washer (6)
Not Sold Separately
Template (Not Shown)
Not Sold Separately