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216 Posts
Discussion Starter #1
Well with the start of the Hannigan trike conversion just days away I pondered whether I really needed to do a clutch change beforehand. I noticed some oil stains and streaking at the transmission/clutch housing seam but just ignored it as minor seepage. Before my last big trip I drilled a weep hole in the clutch housing and got some drainage of trans lub which amounted to maybe ¼ teaspoon or less. The clutch wasn’t slipping, it didn’t seem all that bad, what do I do? Fast forward to last week, I decided at the last minute there was no way I wanted to do a clutch change after the trike changeover so parts were ordered, I already had a Siebenrock clutch in hand for future use so away I did venture. Things went fairly smooth at dissy except for the transmission removal which was hitting the frame before clearing the mount, (see second picture). Once inside I realized how oily it really was. The clutch plate didn’t look all that bad but I think it was only a matter of time. Engine oil seal wasn’t leaking but the trans input shaft seal was. To be continued…………..
 

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Wrencher Extraordinaire
2005 K1200LT
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13,921 Posts
The clutch looks pretty good. But measure it and see how close it is to the wear limit. The tranny looks really clean as well. Must be fairly low mileage. Typically the engine main does not leak but the 19x4 o-ring on the shaft does get hard and will eventually leak oil.

I use 1/4 inch bolts to temp replace the front engine mount bolts. That gives some swing leway as you drop the back of the engine to get the tranny to clear. Much easier now that after the conversion.
 

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Premium Member
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216 Posts
Discussion Starter #3
Re: Clutch replacement before Hannigan conversion (part two)

After removing the clutch housing and cleaning things up I removed the rear main seal on the engine for replacement. I hadn’t made an installation tool for this seal so I just used a fiber drift and hammer, “dumb move”! Seal was almost completely seated but I wanted to give it just one more shot and that’s when the hammer handle hit the frame and I struck the drift at an angle. Put a nice crease in the seal face but I thought it’ll probably be OK, so I started to reassemble it. Getting late so I’ll continue this the next day. That night it bothered me about the seal so what did I do----- ordered another seal!!! Fabricated a tool per advice from the forum experts and installed the new seal a few days later, “much better”!! Replaced everything rearward of the engine seal except the clutch housing, this included new hex nut, compression ring and o-ring. I probably went a little overboard by replacing all the clutch components including bolts and star washers but I don’t even want to ponder back in there any time soon, of course that’s no guarantee I won’t have to!!............Final chapter coming soon............
 

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Great job! I proudly hung the nut right next to the little bell on the back of my bike just to show I've been there, done that! :thumb:
It also looks better than those redneck "nuts" some pickups have hanging from their tow hitches! :wtf: :wack:
 

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Discussion Starter #5
Re: Clutch replacement before Hannigan conversion (final)

I replaced all the seals in the transmission, drilled the weep hole in the slave housing, increased the weep hole size slightly in the clutch housing and continued reassembly, finally installing the last bolt on Sunday May 20 around 7:00 pm. Most of the reassembly went smoothly except for an occasional “Oh $h1t” where I had to take something back off because I forgot to put something on before it. It almost seems pointless to put the bike all back together just to have them take it apart again in a few days for the Hannigan kit. In closing, I would just like to personally thank jzeiler, BlauBeeMr, southern_nj and anyone else who have posted video, instructional data or contributed prior actual hands on experience ideas, which I relied on heavily, for this type of repair. For without this would have been much more difficult if not almost impossible for me to perform. Thanks again men, your efforts are exceptional………………..Rob
 
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