Harley Davidson 2011 Touring Models. Service Manual — page 39
1
2
4
5
3
sm02410a
1. Shoe assembly
2. Wedge
3. Washer
4. Spring
5. Spring rod
Figure 5-14. Primary Chain Tensioner Assembly
2
3
1
sm02411
1. Shoe
2. Spring rod
3. Roll pin
Figure 5-15. Spring Rod Location
1
2
sm02412
1. Shoe
2. Wedge
Figure 5-16. Primary Chain Tensioner
1
2
sm02413
1. Primary chain tensioner
2. Cable tie
Figure 5-17. Securing Primary Chain Tensioner
1
2
sm06987
1. Chain tensioner
2. Chain tensioner fasteners
Figure 5-18. Chain Tensioner
2011 Touring Service: Drive 5-9
5.5
PRIMARY CHAINCASE HOUSING
REMOVAL
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
1.
Disconnect negative battery cable.
2.
Remove primary chaincase cover. See
3.
Remove starter. See
4.
Remove primary chain, clutch, and compensating sprocket.
See
.
5.
See
. Remove five sealing fasteners (5) and
remove primary chaincase housing (11). Discard the
crankcase gasket (10) and sealing fasteners.
1
2
3
6
5
4
8
9
7
10
11
sm05037
1. Seal
2. Lock ring
3. Bearing
4. Dowel pin
5. Sealing fastener (5)
6. Chain tensioner fasteners
7. Chain tensioner
8. Drain plug and O-ring
9. Shifter shaft bushings
10. Crankcase gasket
11. Primary chaincase housing
Figure 5-19. Primary Chaincase Housing
INSPECTION
1.
Inspect primary chaincase for cracks or damaged gasket
surface.
2.
Check the mainshaft bearing. Replace if bearing does not
rotate freely. Replace the lip seal. See
CHAINCASE HOUSING, Mainshaft Bearing and Lip Seal
3.
Inspect shifter shaft bushings. Replace if worn or dam-
aged. See
5.5 PRIMARY CHAINCASE HOUSING, Shifter
MAINSHAFT BEARING AND LIP SEAL
Removal
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
1.
Remove lip seal from bearing bore on transmission side
of primary chaincase. Use a seal remover or rolling head
pry bar for best results.
2.
Remove retaining ring from groove on transmission side
of bearing.
3.
Support inner primary chaincase on transmission side of
bearing.
NOTE
Support inner primary chain case area on transmission side
while pressing bearing out of primary chaincase. The force
needed to remove bearing may cause damage to primary chain
case.
4.
Place primary chaincase in arbor press. Press out bearing
from clutch side applying pressure to the outer race.
Installation
1.
Inspect the bearing bore to verify that it is clean and
smooth. Install retaining ring in groove on pulley side of
primary chaincase.
2.
Place primary chaincase in arbor press with the transmis-
sion side up.
3.
Support the bearing support area on the clutch side of the
primary chaincase.
NOTE
Support the bearing support area on clutch side while pressing
bearing into bore. The force needed to press bearing into
position may force and unsupported primary chain case to
become damaged.
4.
Apply a thin film of oil to outer diameter of bearing.
5.
Applying pressure to the outer race, press
new
bearing
letter side up, into bore until it makes solid contact with
the bearing support area.
6.
See
. Retaining ring (1) must be oriented as
shown to prevent blocking of oil passage (2). Install
retaining ring to lock position of bearing in bore. Verify that
the ring is fully seated in the groove and is in proper orient-
ation.
5-10 2011 Touring Service: Drive
NOTES
•
The lip garter spring side of the oil seal is also identified
by the words "OIL SIDE".
•
Install oil seal with a seal driver that will press only against
outer rim of oil seal, NOT against the inner area.
•
The minimum allowable depth of the seal is reached when
the outer edge of the seal carrier is flush with the machined
surface of the primary housing. The maximum allowable
depth of the seal is reached when the seal carrier contacts
the mainshaft bearing snap ring.
7.
Install mainshaft oil seal:
a.
Lubricate the O.D. of the
new
seal with Screamin'
Eagle Assembly Lube (part No. 94971-09.)
b.
See
. With the lip garter spring side
(stamped "oil side") facing toward the bearing, press
squarely on the outer edge of oil seal until outer edge
of seal is flush with machined surface of inner primary
housing.
8.
Lubricate the bearing and seal lip with multi-purpose
grease or Screamin' Eagle Assembly Lube (part No.
94971-09.)
2
1
sm02385
1. Retaining ring
2. Oil passage
Figure 5-20. Retaining Ring Orientation
sm02387
Figure 5-21. Oil Seal
MAINSHAFT BEARING INNER RACE
TOOL NAME
PART NUMBER
MAINSHAFT BEARING INNER RACE
REMOVER/INSTALLER
HD-34902-C
Removal
NOTE
The bearing inner race must be positioned on the shaft a pre-
cise distance to properly align with the bearing outer race in
the primary chaincase. To remove and install the bearing inner
race, use the combination MAINSHAFT BEARING INNER
RACE REMOVER/INSTALLER (Part No. HD-34902-C).
1.
See
. Install end cap (2) into end of mainshaft.
2.
Position puller (3) around mainshaft, under bearing inner
race.
3.
Turn forcing screw (4) clockwise while holding puller to
remove bearing.
4
3
2
1
sm05961
1. Bearing inner race
2. End cap
3. Puller
4. Forcing screw
Figure 5-22. Pulling Mainshaft Inner Bearing Race
2011 Touring Service: Drive 5-11
Installation
1.
See
. Slide bearing inner race (1) onto main-
shaft.
NOTE
Extension shaft has left-hand threads.
2.
Thread extension shaft (2) onto end of mainshaft.
3.
Position installer sleeve (4) over extension shaft and
against bearing inner race. Apply graphite lubricant to
threads of extension shaft.
4.
Place two washers (5) over threaded portion of extension
shaft and install nut.
5.
Tighten nut (6) while holding extension shaft stationary
with wrench on flats (3) at end of screw threads. Press
race onto shaft until edge of race contacts step on shaft.
6.
Lubricate race with Screamin' Eagle Assembly Lube (Part
No. 94971-09.)
1
2
3
4
5
6
sm03455
1. Bearing inner race
2. Extension shaft
3. Wrench flat
4. Installer sleeve
5. Washers
6. Nut
Figure 5-23. Installing Bearing Race
SHIFTER SHAFT BUSHINGS
1.
See
. Press out old bushings (1) using an arbor
press. Inspect the bushing bore to verify that it is clean
and smooth.
2.
Press
new
bushings into each side of the bore using an
arbor press. Installed bushing must be flush to 0.010 in.
(0.25 mm) below edge of bore.
1
1
2
sm05050
1. Shifter shaft bushing (2)
2. Primary chaincase
Figure 5-24. Shifter Shaft Bushings
INSTALLATION
NOTE
Cover mainshaft clutch hub splines with tape to prevent the
splines damaging the inner primary cover oil seal.
1.
Verify pivot shaft torque. See
NOTE
See
. In next step, be sure dowels (1) in crankcase
gasket (2) engage holes in crankcase.
2.
See
. Place crankcase gasket in place on
gasket surface (2). Be sure dowels in gasket engage dowel
holes (3).
3.
Spread a thin film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket. Be careful not to damage
mainshaft seal when installing chaincase over the primary
bearing inner race on the mainshaft.
4.
See
. Insert
new
sealing fasteners.
5.
See
. Tighten fasteners in sequence shown to
25-27 ft-lbs (33.9-36.6 Nm).
6.
Install the primary chain, clutch, and compensating
sprocket as an assembly. See
.
7.
Install chain tensioner assembly.
8.
Install starter. See
.
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
5-12 2011 Touring Service: Drive
9.
Install primary chaincase cover. See
10. Fill primary chaincase with lubricant. See
CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant
.
11. Adjust rear belt tension.
12. Connect negative battery cable.
2
1
1
sm02381
1. Dowel
2. Crankcase gasket
Figure 5-25. Crankcase Gasket
2
1
3
3
sm02382
1. Crankcase
2. Gasket surface
3. Dowel holes
Figure 5-26. Crankcase
sm02383
Figure 5-27. Sealing Fastener
5
2
3
1
4
sm05039
Figure 5-28. Sealing Fastener Torque Sequence
2011 Touring Service: Drive 5-13
5.6
CLUTCH
REMOVAL AND INSTALLATION
To remove the clutch without disassembly or for installation
instructions, see
CLUTCH PACK ONLY
Partial Disassembly
This procedure can be performed on the motorcycle without
removing the clutch shell or hub.
1.
Remove primary chaincase cover. See
2.
See
. Remove six bolts (1) (metric) to release
diaphragm spring retainer (2) from clutch hub. Loosen
each bolt gradually and in a star sequence around the
hub.
3.
Remove diaphragm spring retainer, diaphragm spring (3)
and pressure plate (4) from clutch hub.
4.
Remove friction plates (5, 7), steel plates (6), damper
spring (8) and damper spring seat (9) from clutch hub (11).
Cleaning And Inspection
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Blow parts dry with low pressure
compressed air.
2.
Check
friction plates
as follows:
a.
Blow off all lubricant from the friction plates. Do not
wipe off with a rag.
b.
Measure the thickness of each plate with a dial caliper
or micrometer.
c.
If the thickness of any plate is less than 0.143 in. (3.62
mm), discard all friction plates and replace with an
entirely
new
set.
d.
Look for worn or damaged fiber surface material (both
sides).
NOTE
Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage. Submerge
and soak all friction plates in primary chaincase lubricant for
at least five minutes.
3.
Check the
steel plates
as follows:
a.
Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
b.
Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 in. (0.15 mm).
4.
Holding the clutch hub, rotate the clutch shell to check
bearing for smoothness. Replace the bearing if it runs
rough, binds or has any end play.
5.
Check the primary chain sprocket and the starter ring gear
on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.
6.
Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
worn or damaged.
NOTE
Springs are identified by a dab of paint on one face. Refer to
the parts catalog to verify the correct spring is installed.
7.
Check the diaphragm spring and diaphragm spring retainer
for cracks or bent tabs. Obtain a
new
diaphragm spring
or diaphragm spring retainer if either condition exists.
5-14 2011 Touring Service: Drive
2
3
1
10
4
12
9
8
7
6
5
15
11
13
14
sm02704b
9.
1.
Damper spring seat
Bolt (6) (metric)
2.
10.
Diaphragm spring retainer
Mainshaft nut (metric)
11.
3.
Clutch hub
Diaphragm spring
4.
12.
Pressure plate
Clutch shell
13.
5.
Bearing
Friction plate (9)
6.
14.
Steel plate (8)
Retaining ring
15.
7.
Retaining ring
Narrow friction plate
8. Damper spring
Figure 5-29. Clutch Shell Assembly
Assembly
NOTE
Submerge and soak all friction plates in primary chaincase
lubricant for at least five minutes.
1.
See
. Install the narrow friction plate on the
clutch hub. Engage tabs on plate with slots in clutch shell.
2.
See
. Install damper spring seat (9) on clutch
hub (11). It must sit inboard of narrow friction plate (7).
2011 Touring Service: Drive 5-15
NOTE
See
. Notice damper spring (4) orientation with
respect to damper spring seat (3).
3.
See
. Install damper spring (8) on clutch hub
with the concave side out (facing away from damper spring
seat).
4.
Install a steel plate (6) with round edge outward and then
a friction plate (5) on the clutch hub. Install seven
remaining sets in the same manner, alternating between
steel plates and friction plates.
5.
Install pressure plate (4) on clutch hub aligning holes in
plate with threaded bosses on hub.
6.
Seat diaphragm spring (3) in recess of pressure plate with
the concave side inward.
7.
Align holes in diaphragm spring retainer (2) with threaded
bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.
8.
Install six bolts (1) (metric) to secure diaphragm spring
retainer to clutch hub. Alternately tighten the bolts to 70-
100
in-lbs
(7.9-11.3 Nm).
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
9.
Install primary chaincase cover and gasket. See
5.3 PRIMARY CHAINCASE COVER, Installation
.
10. Fill primary chaincase with lubricant. See
CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant
.
1
2
sm02417
1. Narrow plate
2. Regular plate
Figure 5-30. Friction Plates
CLUTCH PACK AND BEARING
Complete Disassembly
1.
Remove the primary chaincase cover. See
2.
Remove clutch assembly. See
3.
Follow
all
partial
disassembly
information
under
NOTE
To avoid possible bearing damage, do not disassemble the
clutch shell and hub assembly unless the bearing, hub or shell
require replacement. Replace the bearing if disassembled.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
4.
See
. With the transmission side up, remove
retaining ring from clutch hub groove.
5.
See
. Supporting clutch shell in same orienta-
tion, use arbor press and a suitable press plug to press
hub from bearing in clutch shell.
6.
See
. With the transmission side up, remove
retaining ring from groove in clutch shell bore.
7.
See
. Turn clutch shell over so that transmis-
sion side is down. Using arbor press and a suitable press
plug, press on inner race to remove bearing from clutch
shell bore.
8.
Continue with Cleaning and Inspection found under
sm02419
Figure 5-31. Clutch Hub Retaining Ring
5-16 2011 Touring Service: Drive
sm02421
Figure 5-32. Pressing Clutch Hub From Bearing
Assembly
1.
Orient clutch shell in arbor press with transmission side
up. Be sure to support clutch shell bore on sprocket side
to avoid damage to ears on clutch basket. Using a suitable
press plug, press against outer race until bearing contacts
shoulder in clutch shell bore.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
2.
See
. Install retaining ring in groove of clutch
shell bore so that flat side of retaining ring is towards
bearing.
3.
Turn clutch shell over so sprocket side is up. Center hub
in bearing. Be sure that bearing inner race is supported
with sleeve on transmission side. Press hub into bearing
until hub shoulder contacts bearing inner race.
4.
See
. Turn assembly over so that the transmis-
sion side is up. Install retaining ring in groove of clutch
hub.
5.
Place clutch assembly on bench oriented with the trans-
mission side down.
6.
Soak all friction and steel plates in primary chaincase
lubricant for at least five minutes.
7.
See
. Install the narrow friction plate on the
clutch hub engaging tabs on plate with slots in clutch shell.
8.
Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.
9.
Install damper spring on clutch hub with the concave side
up (facing opposite damper spring seat).
10. Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
alternating between steel plates and frictions plates.
11. Install pressure plate on clutch hub aligning holes in plate
with threaded bosses on hub.
12. See
. Seat diaphragm spring (1) in recess of
pressure plate with the concave side down.
13. Align holes in diaphragm spring retainer with threaded
bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.
14. Install six bolts (5) (metric) to secure diaphragm spring
retainer to clutch hub. Alternately tighten 70-100
in-lbs
(7.9-11.3 Nm).
15. Install clutch. See
5.4 DRIVE COMPONENTS, Installation
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
16. Install primary chaincase cover and gasket. See
5.3 PRIMARY CHAINCASE COVER, Installation
17. Fill primary chaincase with lubricant. See
CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant
.
sm02422
Figure 5-33. Install Clutch Shell Retaining Ring with Flat
Side Against Bearing
2011 Touring Service: Drive 5-17
sm02424
Figure 5-34. Pressing Bearing From Clutch Shell
5
2
7
6
1
3
4
sm02426
1. Steel plate
2. Clutch hub
3. Damper spring seat
4. Damper spring
5. Starter ring gear
6. Primary chain sprocket
7. Narrow friction plate
Figure 5-35. Clutch Stackup
5
4
3
2
1
sm02427
1. Diaphragm spring
2. Jamnut
3. Adjuster screw
4. Retaining ring
5. Bolt (6) (metric)
Figure 5-36. Assembled Clutch
5-18 2011 Touring Service: Drive
5.7
TRANSMISSION SPROCKET
REMOVAL
TOOL NAME
PART NUMBER
FINAL DRIVE SPROCKET LOCKING
TOOL
HD-46282A
MAINSHAFT LOCKNUT WRENCH
HD-47910
PILOT
HD-94660-2
1.
Remove primary chaincase. See
2.
Loosen drive belt tension. See
NOTE
Remove sprocket nut only while transmission is installed in
frame. Failure to do so will result in damage to transmission
and/or transmission stand.
3.
See
. Remove two screws (1) and lockplate
(2).
4.
See
. Install FINAL DRIVE SPROCKET
LOCKING TOOL (Part No. HD-46282A) (2) so that arm
of tool rests against bottom of rear fork pivot (1).
NOTE
Sprocket nut has a right-hand thread.
5.
Install PILOT (Part No. HD-94660-2) on mainshaft.
6.
Remove the sprocket nut (3) using MAINSHAFT
LOCKNUT WRENCH (Part No. HD-47910) (1).
7.
Remove sprocket, allowing belt to slip from sprocket as
sprocket is removed.
4
5
3
2
1
sm02428
1. Screw (2)
2. Lockplate
3. Sprocket nut
4. Sprocket
5. Main drive gear
Figure 5-37. Transmission Sprocket
2
1
3
sm05983
1. Rear fork pivot
2. Final drive sprocket locking tool
3. Sprocket nut
Figure 5-38. Sprocket Nut Removal
CLEANING AND INSPECTION
1.
Using a non-volatile cleaning solvent, clean sprocket of
all grease and dirt.
2.
Inspect belt and sprocket. See
3.
Inspect both main drive gear and mainshaft seals. Replace
if damaged.
INSTALLATION
TOOL NAME
PART NUMBER
FINAL DRIVE SPROCKET LOCKING
TOOL
HD-46282A
MAINSHAFT LOCKNUT WRENCH
HD-47910
PILOT
HD-94660-2
NOTE
Install sprocket nut only while transmission is installed in frame.
Failure to do so will result in damage to transmission and/or
transmission stand.
1.
Place transmission sprocket in position. Install the belt on
the sprocket as the sprocket is installed.
2.
If reusing the sprocket nut, apply Loctite High Strength
Threadlocker 271 (red) to the threads of the sprocket nut.
NOTES
•
Exercise caution to avoid getting oil on the threads of the
sprocket nut or the integrity of the lock patch may be
compromised.
•
The transmission sprocket nut has right-hand threads.
Turn the nut clockwise to install on the main drive gear.
3.
See
. Carefully spread a small quantity of clean
engine oil on the inside face of the sprocket nut (3) and
the outside face of the sprocket (4) where the surfaces of
2011 Touring Service: Drive 5-19
the two parts contact each other. Install the sprocket nut
until finger tight.
4.
See
. Lock transmission sprocket with the
FINAL DRIVE SPROCKET LOCKING TOOL (Part No. HD-
46282A) (2). Arm of locking tool must rest against upper
portion of rear fork pivot (1).
5.
Install PILOT (Part No. HD-94660-2) on mainshaft.
6.
Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
47910), tighten sprocket nut to 100 ft-lbs (135.7 Nm) initial
torque.
7.
See
. Relocate locking tool as when removing
sprocket nut.
8.
Loosen sprocket nut one full turn.
9.
Relocate locking tool as shown in
10. Tighten sprocket nut to 35 ft-lbs (47.5 Nm).
11. See
. Scribe lines (3) on the transmission
sprocket nut (1). Continue the lines onto the transmission
sprocket (2) as shown.
12. Tighten sprocket nut an additional 35-40 degrees.
13. Install lockplate over transmission sprocket nut so that two
of lockplate's four drilled holes align with sprocket's two
tapped holes. To find the best fit, lockplate can be rotated
to a number of positions and can be placed with either
side facing sprocket.
NOTE
Maximum allowable tightening of sprocket nut is 45 degrees
of clockwise rotation after a torque of 35 ft-lbs (47.5 Nm). Do
not loosen sprocket nut to align holes or nut will be under
tightened.
14. If holes in lockplate do not align with those in sprocket,
continue to tighten sprocket nut (up to the 45 degrees
maximum) until sprocket and lockplate holes are in align-
ment.
NOTES
•
New screws have LOCTITE patches.
•
Screws can be re-used up to three times if LOCTITE High
Strength Threadlocker 271 (red) is applied before installa-
tion.
•
To be sure of the lockplate's security, BOTH screws must
be installed in the lockplate.
15. See
. Install two screws (1) to secure lockplate
(2) to sprocket (4).
16. Tighten screws to 90-120
in-lbs
(10.2-13.6 Nm).
17. Install primary chain assembly. See
.
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
18. Install primary chaincase cover and
new
gasket. See
19. Fill primary chaincase with lubricant. See
20. Verify pivot shaft torque. See
21. Adjust belt tension. See
3
2
1
sm05984
1. Rear fork pivot
2. Final drive sprocket locking tool
3. Sprocket nut
Figure 5-39. Sprocket Nut Installation
1
2
3
35°
45°
sm05068a
1. Transmission sprocket nut
2. Transmission sprocket
3. Scribed lines
Figure 5-40. Transmission Sprocket Nut Final Tightening
5-20 2011 Touring Service: Drive
5.8
DRIVE BELT
REMOVAL AND ADJUSTMENT
Adjustment
See
1.12 DRIVE BELT AND SPROCKETS, Setting Belt
.
Removal
1.
Remove rear wheel and rear fork. See
.
2.
Remove primary chain, clutch, engine compensating
sprocket, and chain adjuster as an assembly. See
3.
Remove primary chaincase housing. See
4.
Remove belt from transmission sprocket.
INSTALLATION
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
1.
Install belt over transmission sprocket.
2.
Install the primary chaincase housing. See
CHAINCASE HOUSING, Installation
.
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
3.
Install primary chain assembly and primary chaincase
cover. Fill primary chaincase with lubricant. See
.
4.
Install rear fork and rear wheel. See
5.
Adjust belt tension. See
2011 Touring Service: Drive 5-21
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
TRANSMISSION
6.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
6.5 CLUTCH RELEASE COVER, Assembly and
Installation
10.2-13.6 Nm
90-120
in-lbs
Clutch cable fitting
6.5 CLUTCH RELEASE COVER, Assembly and
Installation
10.2-13.6 Nm
90-120
in-lbs
Clutch release cover screws
6.6 TRANSMISSION ASSEMBLY, Assembly
115.3-128.8 Nm
85-95 ft-lbs
Mainshaft/countershaft nuts
6.8 TRANSMISSION CASE, Installation
13.6-20.3 Nm
120-180
in-lbs
Neutral switch
6.6 TRANSMISSION ASSEMBLY, Assembly
13.6-17.0 Nm
120-150
in-lbs
Shift drum detent arm fastener
6.6 TRANSMISSION ASSEMBLY, Assembly
6.4-7.1 Nm
57-63
in-lbs
Shift drum lock plate fasteners
6.8 TRANSMISSION CASE, Assembly
24.4-29.8 Nm
18-22 ft-lbs
Shifter rod lever screw
6.4 SHIFTER LINKAGE, Shifter Rod
9.0-13.6 Nm
80-120
in-lbs
Shifter rod locknut
6.6 TRANSMISSION ASSEMBLY, Installation
17.6-24.4 Nm
13-18 ft-lbs
Side door fasteners
6.6 TRANSMISSION ASSEMBLY, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
6.8 TRANSMISSION CASE, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
6.8 TRANSMISSION CASE, Installation
46.1-52.9 Nm
34-39 ft-lbs
Transmission mounting bolts, final torque
6.8 TRANSMISSION CASE, Installation
20.3 Nm
15 ft-lbs
Transmission mounting bolts, initial
torque
6.6 TRANSMISSION ASSEMBLY, Installation
10.2-13.6 Nm
90-120
in-lbs
Transmission top cover
6.8 TRANSMISSION CASE, Installation
9.5-14.9 Nm
84-132
in-lbs
VSS fastener
2011 Touring Service: Transmission 6-1
6.2
SPECIFICATIONS: TRANSMISSION
SPECIFICATIONS
Table 6-1. Transmission Specifications
DATA
TRANSMISSION
6-speed forward constant
mesh
Type
Part No. 99851-05 (qt)
FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE
LUBRICANT
Part No. 99824-03/00QT (qt)
SYN3 20W50 Oil
32 oz.
Capacity
946.4 ml
Table 6-2. Transmission Gear Ratios
GEAR RATIO
GEAR
3.34
First (low)
2.31
Second
1.72
Third
1.39
Fourth
1.19
Fifth
1.00
Sixth (high)
NOTE
Final gear ratios indicate the number of mainshaft revolutions
required to drive the output sprocket one revolution.
SERVICE WEAR LIMITS
Table 6-3. Main Drive Gear Specifications
MM
IN.
MAIN DRIVE GEAR (6th)
0.0076-0.043
0.0003-0.0017
Bearing fit in transmission
case (loose)
0.025-0.076
0.001-0.003
Fit in bearing (press-fit)
none
none
End play
Table 6-4. Mainshaft Tolerance Specifications
MM
IN.
MAINSHAFT TOLERANCE
0.00-0.08
0.000-0.003
Mainshaft runout
none
none
Mainshaft end play
0.05-0.66
0.002-0.026
5th gear end play (axial)
0.009-0.052
0.0004-0.0020
5th gear clearance (radial)
0.023-0.056
0.0009-0.0022
Main drive gear (6th) fit
Table 6-5. Countershaft Tolerance Specifications
MM
IN.
COUNTERSHAFT
TOLERANCE
0.00-0.08
0.000-0.003
Countershaft runout
0.025-0.08
0.001-0.003
Countershaft end play
0.03-0.58
0.001-0.023
1st gear end play (axial)
0.010-0.052
0.0004-0.0020
1st gear clearance (radial)
0.03-1.02
0.001-0.40
2nd gear end play (axial)
0.010-0.052
0.0004-0.0020
2nd gear clearance
(radial)
0.03-1.07
0.001-0.042
3rd gear end play (axial)
0.010-0.052
0.0004-0.0020
3rd gear clearance
(radial)
0.03-0.71
0.001-0.028
4th gear end play (axial)
0.010-0.052
0.0004-0.0020
4th gear clearance
(radial)
Table 6-6. Shifter Dog Clearance Specifications
MM
IN.
SHIFTER DOG
0.33-3.07
0.013-0.121
1st
0.41-3.51
0.016-0.138
2nd
0.25-3.17
0.010-0.125
3rd
0.46-3.28
0.018-0.129
4th
0.18-2.97
0.007-0.117
5th
0.56-3.33
0.022-0.131
6th
Table 6-7. Side Door Bearing Specifications
MM
IN.
SIDE DOOR BEARING
0.0025-0.0356
0.0001-0.0014
Fit in side door (tight)
-0.010
-0.0004
Fit on countershaft (tight)
+0.030
+0.0012
Fit on countershaft (loose)
-0.010
-0.0004
Fit on mainshaft (tight)
+0.030
+0.0012
Fit on mainshaft (loose)
Table 6-8. Shifter Fork Specifications
MM
IN.
SHIFTER FORKS
0.102-0.305
0.004-0.012
Shifter fork to cam groove end
play
0.102-0.4060
0.004-0.016
Shifter fork to dog ring end
play
6.55
0.258
First and second gear shift
fork pad thickness wear limit
5.03
0.198
Third and fourth gear shift fork
pad thickness wear limit
6.55
0.258
Fifth and sixth gear shift fork
pad thickness wear limit
6-2 2011 Touring Service: Transmission
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