So I've searched high and low and haven't found this as something discussed before.

I bought a 2002 Sportster with 19k miles on it back in September 18. It's my first bike and I'd never ridden until I got it.

The issue I'm having is random but mostly happens when cold.

When I put it in first and take off from a stop I get a clattering from the primary/clutch side and the bike feels like its grabbing the whole time it's making the noise. The clutch lever is fully released. It will stop after a couple of seconds and then no issues. It only happens in first gear. No grabbing or slipping noticeable in any other gear. I've only put 75 or so miles on it since the end of April and didn't even take it out of the shop between September and late April.

Has fresh crankcase and primary oil. The primary oil was Harley as I told them what bike I had and that's the primary oil they gave me. It was all changed in December but no miles were put on it until Late April as explained above.

Things I've done since purchase of bike.

1. Changed fluids
2. Checked the primary chain adjustment and it seems to be fine.
3. Changed plugs and wires - Champion RA8HC gapped at .040 and Drag Specialties 8.8mm wires

 

Could be the spring plate in the clutch.

 

Do a complete clutch and cable adjustment by the book.

 

Was just about to walk out the door to do that after watching some YouTube videos on how to do it. Not sure that's "by the book" but they are pretty consistent.

 

I get that too....when cold..then hot too...

Was told to change the fluid....

Sorce

 

I meant the shop manual, but if you don't have one then the videos should be fine.

 

+1 and at 19K it could have failed. I'd take it apart and eliminate the spring plate even if it hasn't failed yet. Rivets were loose on mine at 10K but I caught it in time, ended up replacing the spring plate with XR1200 judder spring parts. The photo below shows what can happen when they fail (not mine, is from another thread here)

 

Got any pics of this? New to me.

 

Made the clutch adjustment. Had to do take the cover off twice as after the first attempt I couldn't get it to go into any gear.

Anyways, looks like that was what it needed. I rode about 40-50 miles after I put it all back together. All country roads with lots of stops and starts. No issues so far.

 

Sure...basically the first friction plate is replaced with the XR1200 parts in the photo, then the original first plate is used along with two steel plates to replace the spring plate. I originally did just the two steel plates plus a friction plate to replace the spring plate but then got a VERY annoying squeal when taking off in first gear (this is quite common) plus clutch takeup was abrupt, going to the XR1200 setup eliminated both of these problems. Total cost for the five parts required is about $70 from one of the discount HD parts outlets. I don't know if anyone else has done this, I got the idea while perusing HD clutch diagrams and parts lists...but hard to imagine I'm the first to come up with this idea.
FWIW sent this info to HD's customer suggestions email box months ago but got no reply. The spring plate they have been using since 1991 has caused a LOT of grief and this fix is so simple and total cost difference at the factory would probably be close to zero dollars. But who knows, maybe HD will make this change eventually...