Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 21
HOME
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10
9
11
7
8
4
12
5
13
4
3
2
6
1
15
16
14
17
17
27
23
22
26
21
25
24
20
41
17
40
19
18
39
38
37
36
35
29
34
28
33
32
31
30
1.
Ball bearing
15. Insulating boot
29. Gasket
2.
Armature
16. Flange nut
30. Screw (2)
3.
Ball bearing
17. Starter repair kit
31. Drive housing
4.
O-ring (2)
18. Ball
32. O-ring
5.
Yoke assembly
19. Return spring
33. Retaining ring
6.
Brush holder
20. Idler bearing retainer
34. Pinion stop nut
7.
Brush spring (4)
21. Clutch roller (5)
35. Pinion gear
8.
End cover
22. Idler gear
36. Spring
9.
Drain vent
23. Solenoid housing
37. Retainer
10. Through bolt
24. Solenoid plunger
38. Clutch
11. Thread protector cap
25. Gasket
39. Spring
12. Through bolt
26. Solenoid cover
40. Output shaft
13. Screw w/O-ring (2)
27. Screw w/washer (3)
41. Clutch sub-assembly
14. Field wire w/terminal
28. Screw (2)
Figure 5-4. Starter Assembly
2006 Sportster: Starter
5-7
HOME
DISASSEMBLY, INSPECTION AND
4860
REPAIR
1.
See Figure 5-4. Remove insulating boot (15), flange nut
(16) and field wire terminal (14).
2.
See Figure 5-5. See Figure 5-4. Remove through bolts
(10, 12).
3.
See Figure 5-6. See Figure 5-4. Remove two cover
screws with O-rings (13), and end cover (8).
4.
See Figure 5-7. See Figure 5-4. Use a wire hook to pull
upward on brush springs (7), and lift brushes out of
brush holder (6). Remove brush holder.
5.
Check brush length. Replace all four brushes if length of
any one brush is less than 0.433 in. (11.0 mm).
NOTE
Brushes are not available separately. See Figure 5-4. To
replace brushes, install a new yoke assembly (5) and brush
holder (6).
Figure 5-5. Removing the Thru-Bolts
6.
See Figure 5-4. Remove armature (2) from yoke assem-
bly (5).
7.
Place armature in lathe or truing stand and check runout
3548a
of commutator. Commutators with more than 0.016 in.
(0.41 mm) of runout should be replaced, or machined on
a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (28.98 mm).
CAUTION
Do not use sandpaper or emery cloth to remove burrs on
commutator. Otherwise, abrasive grit may remain on
commutator segments; this could lead to excessive
brush wear. Use only the recommended crocus cloth.
8.
Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.203 mm), use an undercutting machine
to undercut the mica to 0.003 in. (0.794 mm) deep. The
slots should then be cleaned to remove any dirt or cop-
per dust.
Figure 5-6. Removing End Cover
3540a
Figure 5-7. Removing Brush Holder
5-8
2006 Sportster: Starter
HOME
d0632x5x
Starting groove in mica
with 3 cornered file
Mica must not be left with a
thin edge next to segments
Mica
Segments
Wrong way
Mica must be cut away
clean between segments
Mica
Undercutting mica with
Segments
piece of hacksaw blade
Right way
Figure 5-8. Undercutting Mica Separators
NOTE
1782a
See Figure 5-8. If an undercutting machine is not available,
undercutting can be done satisfactorily using a thin hacksaw
blade. After undercutting, lightly sand the commutator with
crocus cloth to remove any burrs.
9.
See Figure 5-9. Check for SHORTED ARMATURE with a
growler.
a. Place armature on growler.
b. Hold a thin steel strip (hacksaw blade) against arma-
ture core and slowly turn armature. A shorted arma-
ture will cause the steel strip to vibrate and be
attracted to the core.
c. Replace a shorted armature.
10. See Figure 5-10. Check for a GROUNDED ARMATURE
with an ohmmeter or continuity tester.
Figure 5-9. Shorted Armature Test Using Growler
a. Touch one probe to any commutator segment.
b. Touch the other probe to the armature core. There
should be no continuity (infinite ohms). If there is
6011
continuity, then the armature is grounded.
c. Replace a grounded armature.
No continuity (∞ ohms)
Figure 5-10. Grounded Armature Test
2006 Sportster: Starter
5-9
HOME
11. See Figure 5-11. Check for OPEN ARMATURE with an
13. Check for OPEN FIELD WINDING with an ohmmeter or
ohmmeter or continuity tester.
continuity tester.
a. Check for continuity between all commutator seg-
a. Touch one probe to the field wire.
ments. There should be continuity (0 ohms) at all
b. Touch the other probe to each of the brushes
test points. No continuity at any test point indicates
attached to the field coils. There should be continu-
armature is open.
ity. If there is no continuity at either brush, then the
b. Replace an open armature.
field winding(s) are open.
c. Replace a field frame with open field winding(s).
14. See Figure 5-13. Test BRUSH HOLDER INSULATION
6012a
with an ohmmeter or continuity tester.
a. Touch one probe to holder plate.
b. Touch the other probe to each of the positive (insu-
lated) brush holders. There should be no continuity
Continuity (0 ohms)
(infinite ohms).
c. If there is continuity at either brush holder, replace
the brush holder assembly.
15. See Figure 5-4. Check armature bearings (1, 3) and
replace if necessary.
x0248x5x
Figure 5-11. Open Armature Test
12. See Figure 5-12. Check for GROUNDED FIELD WIND-
ING with an ohmmeter or continuity tester.
a. Touch one probe to the frame.
b. Touch the other probe to each of the brushes
attached to the field winding. There should be no
continuity (infinite ohms). If there is any continuity at
either brush, then the field winding(s) are grounded.
c. Replace a field frame with grounded field winding(s).
No continuity (∞ ohms)
6014a
Figure 5-13. Brush Holder Insulation Test
Figure 5-12. Open and Grounded Field Test
5-10
2006 Sportster: Starter
HOME
16. See Figure 5-14. Remove two drive housing mounting
ASSEMBLY
screws (with washers and lock washers). Remove drive
housing from solenoid housing.
CAUTION
3549a
See Figure 5-15. See Figure 5-4. Do not use solvents to
clean starter clutch (38). It is pre-lubricated and sealed. If
you use solvent to clean starter clutch, the lubricant will
be washed out and the clutch will fail.
1. See Figure
5-15. Clean, inspect, and lubricate drive
assembly components. Lubricate parts with high temper-
ature grease, such as LUBRIPLATE 110.
2. See Figure 5-4. When installing drive assembly compo-
nents, open end of idler bearing retainer
(20) faces
toward solenoid.
3. When assembling solenoid housing (23), yoke assembly
(5) and end cover (8), use new O-rings (4).
4. When installing drive housing (31) to solenoid housing,
Figure 5-14. Removing Starter Drive Housing
use new O-ring (32). Be sure to install return spring (19)
and ball (18).
17. See Figure 5-15. Remove drive, idler gear, idler gear
bearing, and O-ring from drive housing (O-ring is located
5. Lubricate armature bearings (1, 3) and felt washer (883
only) with high temperature grease, such as LUBRI-
in drive housing groove).
PLATE 110. Install armature (2) and yoke assembly (5)
to solenoid housing.
3530a
6. Inspect brush springs and replace if necessary. Install
brushes and brush holder (6).
7. Install end cover (8) with screws (13) and O-rings (1200
only).
8. Install through bolts (10, 12). Tighten to 39-65 in-lbs
(4.4-7.4 Nm).
9. Install field wire terminal
(14), secure with flange nut
(16). Tighten to 70-90 in-lbs (7.9-10.2 Nm). Snap insu-
lating boot (15) in place.
Figure 5-15. Starter Drive Assembly
2006 Sportster: Starter
5-11
HOME
INSTALLATION
1
WARNING
1.
Install starter and starter gasket from right side of motor-
Connect positive (+) battery cable first. If positive (+)
cycle.
cable should contact ground with negative (-) cable con-
2.
See Figure 5-3. Install two starter mounting bolts and
nected, the resulting sparks can cause a battery explo-
washers. Tighten to 13-20 ft-lbs (17.6-27.1 Nm).
sion, which could result in death or serious injury.
3.
Install positive
(+) battery cable and solenoid wire to
(00068a)
solenoid stud. Tighten nut to 60-85 in-lbs (6.8-9.6 Nm).
7. Open left side cover. No tools are required. See 1.6
Place rubber boot securely over terminal.
LEFT SIDE COVER.
4.
Install primary cover. See Primary Cover INSTALLA-
8. Connect positive (+) battery cable to battery positive (+)
TION under 6.3 PRIMARY CHAIN ADJUSTER.
terminal. See 1.7 BATTERY MAINTENANCE. Close left
5.
Fill primary chaincase / transmission with proper lubri-
side cover.
cant; see 1.14 TRANSMISSION LUBRICANT for details.
9. Connect negative (-) battery cable to stud on engine
6.
Install rear exhaust pipe and muffler. See
2.27
crankcase behind starter motor assembly. See 1.7 BAT-
EXHAUST SYSTEM.
TERY MAINTENANCE.
5-12
2006 Sportster: Starter
HOME
STARTER SOLENOID
5.5
GENERAL
x0256b6x
1
The starter solenoid is a switch that is designed to open and
4
close the starting circuit electromagnetically. The switch con-
sists of contacts and a winding around a hollow cylinder con-
5
taining a movable plunger.
6
If starter assembly is mounted in vehicle, prepare vehicle for
solenoid disassembly as follows:
1WARNING
Prevent accidental vehicle start-up, which could cause
3
death or serious injury. First disconnect negative (-) bat-
tery cable at engine and then positive (+) cable from bat-
tery. (00280a)
2
1.
Sprocket cover
1.
Remove negative (-) battery cable from stud on engine
2.
Screw
crankcase boss behind starter motor assembly. See 1.7
3.
Screw
BATTERY MAINTENANCE.
4.
Exhaust pipe clamp bracket
5.
Washer
2.
Open left side cover. No tools are required. See 1.6
6.
Screw
LEFT SIDE COVER.
3.
Remove positive (+) battery cable from battery positive
Figure 5-16. Sprocket Cover
(+) terminal. See 1.7 BATTERY MAINTENANCE.
4.
Close left side cover.
5.
Remove rear muffler and rear exhaust pipe. See 2.27
11480
EXHAUST SYSTEM.
1
6.
See Figure 5-16. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4). Remove two screws (2,
3) and remove sprocket cover (1) from vehicle.
7.
See Figure 5-17. Detach hoses from hose clip (2).
8.
Unscrew lock nut (3) and remove hose clamp (4) from
hoses.
2
4
3
1.
Starter solenoid
2.
Hose clip
3.
Lock nut
4.
Hose clamp
Figure 5-17. Accessing Starter Solenoid on Vehicle
2006 Sportster: Starter
5-13
HOME
DISASSEMBLY
FINAL
If starter assembly is mounted in vehicle, finish assembling
CAUTION
vehicle as follows:
1. See Figure 5-17. Install hose clamp (4) around hoses
See Figure 5-18. Do not tighten nut (8) without removing
and onto stud on starter motor. Secure with lock nut (3).
items 2-6. The contact will move and be destroyed.
2. Attach hose clip (2) to hoses.
1.
See Figure 5-18. Remove three screws (3) and washers
(4).
3. See Figure 5-16. Install sprocket cover (1). Secure with
two screws (2, 3). Note that long screw goes in top hole,
2.
Remove cover (5) and gasket (6). Discard gasket.
short screw in bottom hole. Do not tighten screws at this
3.
Remove plunger (2) from solenoid housing (1).
time.
4. Install exhaust pipe clamp bracket (4), washer (5) and
ASSEMBLY
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
1.
See Figure 5-18. Replace wire connection hardware (7)
5. Install rear exhaust pipe and rear muffler. See
2.27
as necessary.
EXHAUST SYSTEM.
2.
Install plunger (2) in solenoid housing (1).
3.
Install new gasket (6) onto cover (5).
1WARNING
4.
Position cover with gasket onto solenoid housing. Install
Connect positive (+) battery cable first. If positive (+)
three screws (3) and washers (4).
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
6. Open left side cover. No tools are required. See 1.6
LEFT SIDE COVER.
7. Connect positive (+) battery cable to battery positive (+)
terminal. See 1.7 BATTERY MAINTENANCE. Close left
side cover.
8. Connect negative (-) battery cable to stud on engine
crankcase behind starter motor assembly. See 1.7 BAT-
TERY MAINTENANCE.
x0250a5x
2
7
1
3
4
8
5
6
8
1.
Solenoid housing
2.
Plunger
3.
Screw (3)
4.
Washer (3)
5.
Cover
6.
Gasket
7.
Wire connection hardware
7
8.
Nut
Figure 5-18. Starter Solenoid
5-14
2006 Sportster: Starter
HOME
SPECIFICATIONS
6.1
Table 6-1. Primary Drive-Engine-to-Transmission
DOMESTIC
HDI/JAPAN
ITEM
883 CC
1200 CC
883 CC
1200 CC
Engine sprocket
34 teeth
38 teeth
38 teeth
38 teeth
Clutch sprocket
57 teeth
57 teeth
57 teeth
57 teeth
Ratio
1.676:1
1.500:1
1.500:1
1.500:1
Table 6-2. Final Drive-Transmission-to-Rear Wheel
DOMESTIC
HDI/JAPAN
ITEM
883 CC
1200 CC
883 CC
1200 CC
Transmission sprocket
28 teeth
29 teeth
28 teeth
30 teeth
Rear wheel sprocket
68 teeth
68 teeth
68 teeth
68 teeth
Secondary drive belt
136 teeth
137 teeth
136 teeth
137 teeth
**
**
Ratio
2.429:1
2.345:1
2.429:1
2.267:1
* Identified by orange bar and shield emblem on outer surface of belt.
** Identified by green bar and shield emblem on outer surface of belt.
Table 6-3. Transmission
PRIMARY DRIVE/TRANSMISSION LUBRICANT
AMOUNT (ALL MODELS)
Capacity
32 U.S. fl oz. (946 ml)
DOMESTIC
HDI
JAPAN
OVERALL GEAR RATIOS
883 CC
1200 CC
883 CC
1200 CC
883 CC
1200 CC
First gear (low)
10.944
9.454
9.792
9.139
9.647
9.004
Second gear
7.524
6.500
6.732
6.283
6.633
6.190
Third gear
5.834
5.040
5.220
4.872
5.143
4.800
Fourth gear
4.806
4.152
4.301
4.014
4.248
3.965
Fifth gear (high)
4.071
3.517
3.643
3.400
3.643
3.400
* Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.
2006 Sportster: Drive/Transmission
6-1
HOME
NOTE
Service wear limits are given as a guideline for measuring
components that are not new. For measurement specifica-
tions not given under SERVICE WEAR LIMITS, see NEW
COMPONENTS.
Table 6-4. Wet Clutch Multiple Disc Specifications
NEW COMPONENTS
SERVICE WEAR LIMITS
ITEM
IN
MM
IN
MM
CLUTCH PLATE THICKNESS
Friction plate (fiber)
0.0866 ± 0.0031
2.200 ± 0.079
N/A
N/A
Steel plate
0.0629 ± 0.0020
1.598 ± 0.051
N/A
N/A
Clutch pack
N/A
N/A
0.6610 (minimum)
16.787 (minimum)
MAXIMUM ALLOWABLE WARPAGE
Friction plate (fiber)
N/A
N/A
0.0059
0.150
Steel plate
N/A
N/A
0.0059
0.150
6-2
2006 Sportster: Drive/Transmission
HOME
TORQUE VALUES
6.2
ITEM
TORQUE
NOTES
Clutch cable end fitting
36-60 in-lbs
4.1-6.8 Nm
page 6-7
Clutch inspection cover screw
84-108 in-lbs
9.5-12.2 Nm
page 6-7
Clutch inspection cover screw
84-108 in-lbs
9.5-12.2 Nm
page 6-9
Countershaft retaining screw
33-39 ft-lbs
44.8-52.9 Nm
LOCTITE 262 (red), page 6-47
Crankcase fasteners
LOCTITE 262 (red), see text for tightening sequence,
15-19 ft-lbs
20.3-25.8 Nm
page 6-46
Debris deflector screw
36-60 in-lbs
4.1-6.8 Nm
page 6-20
Engine sprocket nut
190-210 ft-lbs
258-285 Nm
page 6-17
Exhaust interconnect bracket
page 6-50
30-33 ft-lbs
40.7-44.8 Nm
screw
Exhaust pipe clamp bracket
page 6-20
30-33 ft-lbs
40.7-44.8 Nm
screw
Exhaust pipe clamp bracket
page 6-50
30-33 ft-lbs
40.7-44.8 Nm
screw
Footrest bracket mounting bolt
45-50 ft-lbs
61.1-67.9 Nm
page 6-9
Front belt guard screw
120-180 in-lbs
13.6-20.3 Nm
page 6-20
Gear shift lever pinch screw
16-20 ft-lbs
21.7-27.1 Nm
page 6-7
Neutral indicator switch
36-60 in-lbs
4.0-6.8 Nm
page 6-46
Primary chain adjuster lock nut
20-25 ft-lbs
27.1-33.9 Nm
page 6-7
Primary cover screw
100-120 in-lbs
11.3-13.5 Nm
See text for tightening sequence, page 6-6
Primary drain plug
14-30 ft-lbs
19.0-40.7 Nm
page 6-7
Rear Axle Nut
72-78 ft-lbs
98-106 Nm
page 6-20
Shock absorber bolt, lower
45-50 ft-lbs
61.1-67.9 Nm
page 6-20
Sprocket cover screw
80-120 in-lbs
9.0-13.6 Nm
page 6-20
Sprocket cover screw
80-120 in-lbs
9.0-13.6 Nm
page 6-50
Transmission mainshaft nut
70-80 ft-lbs
95.0-108.6 Nm
page 6-17
Transmission sprocket nut
See TRANSMISSION SPROCKET section for special
See notes
See notes
(left-hand threads)
procedure. page 6-49
Transmission sprocket nut lock-
page 6-50
90-110 in-lbs
10.2-12.4 Nm
plate
2006 Sportster: Drive/Transmission
6-3
HOME
PRIMARY CHAIN ADJUSTER
6.3
7. Loosen locknut (6). Turn chain adjuster screw (5) coun-
GENERAL
terclockwise to relax primary chain tension.
The primary chain adjuster mechanism maintains proper ten-
8. Remove gear shifter lever and rubber washer from trans-
sion on the primary chain.
mission shifter shaft.
9. See Figure 6-2. Slide rubber boot (1) on clutch cable
An opening between the primary drive and transmission com-
adjuster
(2) upward to expose adjuster mechanism.
partments allows the same lubricant supply to lubricate mov-
Loosen jam nut
(3) from adjuster. Turn adjuster to
ing parts in both areas. Since the primary chain runs in
shorten cable housing until there is a large amount of
lubricant, little service will be required other than checking
freeplay at clutch hand lever. See ADJUSTMENT under
lubricant level and chain tension. If, through hard usage, the
1.13 CLUTCH.
primary chain does become worn, it must be replaced.
Remove and install the chain following the procedure under
6.5 PRIMARY DRIVE/CLUTCH.
8940
2
REMOVAL
1
3
Primary Cover
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect battery cables
(negative (-) cable first) before proceeding. (00307a)
6
1.
Disconnect negative
(-) battery cable from stud on
5
4
engine crankcase behind starter motor assembly. See
1.7 BATTERY MAINTENANCE.
1.
Primary chain inspection cover
2.
Primary cover
2.
Open left side cover. No tools are required. See 1.6
3.
Clutch inspection cover
LEFT SIDE COVER.
4.
Drain plug
3.
Remove positive (+) battery cable from battery positive
5.
Chain adjuster screw
(+) terminal. See 1.7 BATTERY MAINTENANCE.
6.
Locknut
4.
Close left side cover.
Figure 6-1. Primary Cover
5.
Remove left side rider footrest and mounting bracket
assembly.
a. XL 883, XL 883L, XL 883R and XL 1200R models:
see LEFT FOOTREST AND SHIFT LEVER
x0055x6x
ASSEMBLY under 2.33 RIDER FOOT CONTROLS:
1
XL 883, XL 883L, XL 883R, XL 1200R for removal
2
procedure.
3
b. XL 883C and XL 1200C models: see LEFT FOOT-
REST AND SHIFT LEVER ASSEMBLY under 2.34
4
RIDER FOOT CONTROLS: XL 883C, XL 1200C for
removal procedure.
1.
Rubber boot
6.
See Figure 6-1. Place a drain pan under the engine.
2.
Cable adjuster
Remove drain plug (4) and drain lubricant from primary
3.
Jam nut
drive housing.
4.
Cable end
Figure 6-2. Clutch Cable Adjuster Mechanism
6-4
2006 Sportster: Drive/Transmission
HOME
10. See Figure
6-3. Remove six screws
(1) and clutch
13. Remove hook of ramp from cable coupling. Remove
inspection cover (2). Remove quad ring (7) from groove
clutch cable end from slot in coupling. Remove coupling
in primary cover (8).
and ramp assembly.
11. Slide hex lockplate and attached spring (3) from flats of
14. Turn cable end fitting (14) counterclockwise to remove
adjusting screw (9).
clutch cable lower section from primary cover. Remove
O-ring (12) from cable end fitting. Discard O-ring.
12. Turn adjusting screw clockwise to release ramp assem-
bly (5) and coupling mechanism (6). As the adjusting
15. Remove sixteen screws with captive washers (11) secur-
screw is turned, ramp assembly moves forward. Unscrew
ing primary cover to engine crankcase. Remove cover
nut (4) from end of adjusting screw.
and gasket (10). Discard gasket.
16. See Figure 6-4. Remove and discard shifter shaft oil seal
(4).
x0252a6x
15
16
17. Clean all metal parts in a non-volatile cleaning solution
17
or solvent.
4
18
3
1WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
6
Wear safety glasses when working with compressed air.
5
Never use your hand to check for air leaks or to deter-
mine air flow rates. (00061a)
7
18. Blow parts dry with low pressure compressed air.
8
8925
2
1
3
1
2
11
9
4
10
12
13
14
1.
Screw (6)
1.
Screw, 1/4-20 x 1 15/16 in. w/captive washer (16)
2.
Clutch inspection cover
2.
Screw, 1/4-20 x 3/8 in. w/o-ring (2)
3.
Hex lockplate and spring
3.
Screw, 1/4-20 x 5/8 in. TORX w/captive washer (6)
4.
Nut
4.
Shifter shaft oil seal
5.
Ramp assembly (see items 15-18)
6.
Coupling
Figure 6-4. Outer Primary Cover
7.
Quad ring
8.
Primary cover
9.
Adjusting screw assembly
10.
Primary cover gasket
11.
Screw w/captive washer (16)
12.
O-ring
13.
Clutch cable end
14.
Cable end fitting
15.
Outer ramp
16.
Ball (3)
17.
Inner ramp
18.
Retaining ring
Figure 6-3. Clutch Release Mechanism
and Primary Cover
2006 Sportster: Drive/Transmission
6-5
HOME
Primary Chain Adjuster
INSTALLATION
1.
See Figure 6-5. Remove locknut (1) from adjuster screw
(4). Turn adjuster screw out of threaded boss in primary
Primary Chain Adjuster
cover (3).
2.
Slide shoe (5) off plate (7) (shoe must be slid off plate
1. See Figure 6-5. Inspect primary chain adjuster shoe (5).
toward closed or blind side of shoe).
If badly worn or damaged, it must be replaced.
2. Place plate (7) into slot (6) at open end of shoe. Slide
shoe over plate until plate is against closed (blind) side of
8922
shoe.
3
3. Position adjuster inside primary cover (3) with closed
5
side of shoe against cover. Thread adjuster screw (4) all
the way into tapped boss at bottom of primary cover.
7
4. At outside of cover, thread locknut
(1) onto adjuster
screw with nylon sealing surface (2) toward cover. A 1/4-
inch allen wrench may be inserted into end of adjuster
screw to hold it while threading lock nut.
Primary Cover
1. See Figure 6-4. Install new shifter shaft oil seal (4).
4
1
2. See Figure 6-3. Install new gasket (10) on primary cover
(8).
x0253b6x
5
3. Install primary cover and gasket using sixteen screws
with captive washers (11). Tighten to 100-120 in-lbs
(11.3-13.5 Nm) in the sequence shown in Figure 6-6.
10581
11
12
4
1
10
9
13
6
8
3
14
7
7
15
6
16
3
2
5
4
2
1
Figure 6-6. Outer Primary Cover
Screw Tightening Sequence
1.
Locknut
2.
Nylon sealing surface
3.
Primary cover
4.
Adjuster screw
5.
Shoe
6.
Slot
7.
Plate
Figure 6-5. Primary Chain Adjuster Assembly
6-6
2006 Sportster: Drive/Transmission
HOME
4.
Remove foreign material from magnetic drain plug.
14.
See Figure 6-2. Hold cable adjuster (2) with 1/2 inch
Install plug and tighten to 14-30 ft-lbs (19.0-40.7 Nm).
wrench. Using 9/16 inch wrench, tighten jam nut (3)
against cable adjuster. Cover cable adjuster mechanism
5.
Fill transmission to proper level with fresh lubricant. See
with rubber boot (1).
REFILLING LUBRICANT under 1.14 TRANSMISSION
LUBRICANT.
15.
Install left side rider footrest and mounting bracket
assembly.
6.
Install new O-ring (12) over cable end fitting (14) of
clutch cable lower section. Turn fitting clockwise to install
a. XL 883, XL 883L, XL 883R and XL 1200R models:
into primary cover (8). Tighten fitting to 36-60 in-lbs (4.1-
see LEFT FOOTREST AND SHIFT LEVER
6.8 Nm).
ASSEMBLY under 2.33 RIDER FOOT CONTROLS:
XL 883, XL 883L, XL 883R, XL 1200R for installa-
7.
Fit coupling (6) over cable end (13) with rounded side of
tion procedure.
coupling inboard and ramp connector button outboard.
With retaining ring side of ramp assembly (5) facing
b. XL 883C and XL 1200C models: see LEFT FOOT-
inward, place hook of ramp around coupling button and
REST AND SHIFT LEVER ASSEMBLY under 2.34
rotate assembly counterclockwise until tang on inner
RIDER FOOT CONTROLS: XL 883C, XL 1200C for
ramp (17) fits in slot of primary cover (8).
installation procedure.
8.
Thread nut (4) on adjusting screw assembly (9) until slot
16.
Adjust primary chain tension. See ADJUSTMENT under
of screw is accessible with a screwdriver. Fit nut hex into
1.12 PRIMARY CHAIN. When tension is set correctly,
recess of outer ramp (15) and turn adjusting screw coun-
tighten lock nut to 20-25 ft-lbs (27.1-33.9 Nm).
terclockwise until resistance is felt. Back off adjusting
17.
Install rubber washer and gear shift lever on shifter shaft.
screw 1/4 turn.
Secure with pinch screw and washer. Tighten to 16-
9.
Slide lockplate and spring
(3) onto flats of adjusting
20 ft-lbs (21.7-27.1 Nm).
screw. If necessary, turn adjusting screw clockwise
18.
Open left side cover. No tools are required. See 1.6
slightly so that lockplate slides onto flats while also fitting
LEFT SIDE COVER.
within recess of outer ramp.
10.
Install quad ring (7) in groove of primary cover. Verify that
1WARNING
quad ring is fully seated in groove.
11.
Install six screws (1) to secure clutch inspection cover (2)
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
to primary cover. Tighten screws in a crosswise pattern
nected, the resulting sparks can cause a battery explo-
to 84-108 in-lbs (9.5-12.2 Nm).
sion, which could result in death or serious injury.
12.
See Figure 6-2. Turn cable adjuster (2) clockwise away
(00068a)
from jam nut (3) until slack is eliminated.
19. Connect positive (+) battery cable to battery positive (+)
13.
See Figure 6-7. Pull clutch cable ferrule away from clutch
terminal. See 1.7 BATTERY MAINTENANCE.
lever bracket to check free play. Turn cable adjuster as
necessary to obtain 1/16-1/8 in. (1.6-3.2 mm) free play
20. Close left side cover.
between end of cable ferrule and clutch lever bracket.
21. Connect negative (-) battery cable to stud on engine
crankcase behind starter motor assembly. See 1.7 BAT-
TERY MAINTENANCE.
x0257x6x
Figure 6-7. Adjust for 1/16-1/8 in. (1.6-3.2 mm) gap
between ferrule and bracket
2006 Sportster: Drive/Transmission
6-7
HOME
CLUTCH RELEASE MECHANISM
6.4
5. Slide spring (3) with attached hex lockplate (4) from flats
REMOVAL/DISASSEMBLY
of adjusting screw assembly (11).
6. Turn adjusting screw clockwise to release ramp and cou-
NOTE
pling mechanism (6, 7, 8, 9, 12). As the adjusting screw
For clutch adjustment procedure, see 1.13 CLUTCH.
is turned, ramp assembly moves forward. Unscrew nut
(5) from end of adjusting screw.
1WARNING
7. Remove hook of ramp from cable end coupling (12).
Remove clutch cable end (15) from slot in coupling.
To prevent accidental vehicle start-up, which could
8. Remove and discard retaining ring (9) from ramp assem-
cause death or serious injury, remove maxi-fuse before
bly to separate inner ramp
(8) and outer ramp
(6).
proceeding. (00251a)
Remove balls (7) from ramp sockets.
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
x0055x6x
2.
XL 883, XL 883L, XL 883R and XL 1200R models:
remove left side rider footrest and mounting bracket
1
assembly. See LEFT FOOTREST AND SHIFT LEVER
2
ASSEMBLY under 2.33 RIDER FOOT CONTROLS: XL
3
883, XL 883L, XL 883R, XL 1200R.
4
3.
See Figure 6-8. Slide rubber boot (1) on clutch cable
adjuster
(2) upward to expose adjuster mechanism.
Loosen jam nut
(3) from adjuster. Turn adjuster to
1.
Rubber boot
shorten cable housing until there is a large amount of
2.
Cable adjuster
freeplay at clutch hand lever. See ADJUSTMENT under
3.
Jam nut
1.13 CLUTCH.
4.
Cable end
4.
See Figure 6-9. Remove six screws
(1) and clutch
inspection cover (2). Exercise caution to avoid damaging
Figure 6-8. Clutch Cable Adjuster Mechanism
or dislodging quad ring (10) from groove in primary cover
(13).
x0054a6x
1.
Screw (6)
2
2.
Clutch inspection cover
3.
Spring
4
3
4.
Hex lockplate
5
6
5.
Nut
6.
Outer ramp
8
7
10
7.
Ball (3)
8.
Inner ramp
9
9.
Retaining ring
10. Quad ring
11. Clutch adjusting screw assembly
12
12. Coupling
13. Primary cover
14. O-ring
15. Clutch cable end
1
16. Cable end fitting
17. Clutch cable
17
11
14
15
16
13
Figure 6-9. Clutch Release Mechanism
6-8
2006 Sportster: Drive/Transmission
HOME
4.
Slide spring (3) with hex lockplate (4) onto flats of adjust-
CLEANING, INSPECTION AND
ing screw. If necessary, turn adjusting screw clockwise
REPAIR
slightly so that lockplate slides onto flats while also fitting
within recess of outer ramp.
1.
See Figure 6-9. Thoroughly clean all parts in cleaning
5.
Verify that quad ring (10) is fully seated in groove of pri-
solvent and dry with a clean, lint-free cloth.
mary cover (13). Install six screws (1) to secure clutch
2.
Inspect three balls
(7) of release ramp and coupling
inspection cover (2) to primary cover. Tighten screws in a
mechanism (6, 7, 8, 9, 12) and ball socket surfaces of
crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm).
inner ramp (8) and outer ramp (6) for wear, pitting, sur-
6.
See Figure 6-8. Turn cable adjuster (2) clockwise away
face breakdown and other damage. Replace parts as
from jam nut (3) until slack is eliminated.
necessary.
7.
See Figure 6-10. Pull clutch cable ferrule away from
3.
Check hub fit of inner and outer ramps. Replace ramps if
clutch lever bracket to check free play. Turn cable
excessively worn.
adjuster as necessary to obtain 1/16-1/8 in. (1.6-3.2 mm)
4.
Check clutch cable assembly (17) for frayed or worn
free play between end of cable ferrule and clutch lever
ends. Replace cable if damaged or worn. See 2.26
bracket.
CLUTCH CONTROL.
5.
Change or add transmission fluid if necessary. See 1.14
x0257x6x
TRANSMISSION LUBRICANT.
ASSEMBLY/INSTALLATION
1.
See Figure 6-9. Assemble inner and outer ramps.
a. Apply a light coat of multi-purpose grease to balls
(7) and ramps (6, 8).
b. Insert balls in sockets of outer ramp (6).
c. Install inner ramp (8) on hub of outer ramp with tang
on inner ramp 180˚ from hook of outer ramp.
d. Install new retaining ring (9) in groove of outer ramp
hub.
Figure 6-10. Adjust for 1/16-1/8 in. (1.6-3.2 mm) gap
2.
Install ramp assembly.
between ferrule and bracket
a. Fit coupling
(12) over cable end
(15) with the
rounded side inboard, the ramp connector button
8. See Figure 6-8. Hold cable adjuster (2) with 1/2 inch
outboard.
wrench. Using 9/16 inch wrench, tighten jam nut (3)
b. With retaining ring side of ramp assembly facing
against cable adjuster. Cover cable adjuster mechanism
inward, place hook of ramp around coupling button.
with rubber boot (1).
c. Rotate assembly counterclockwise until tang on
9. XL 883, XL 883L, XL 883R and XL 1200R models: install
inner ramp fits in slot of primary cover.
left side rider footrest and mounting bracket assembly.
Tighten footrest bracket mounting bolts to 45-50 ft-lbs
3.
Secure assembly in place.
(61.1-67.9 Nm). See LEFT FOOTREST AND SHIFT
a. Thread nut (5) on adjusting screw assembly (11)
LEVER ASSEMBLY under 2.33 RIDER FOOT CON-
until slot of screw is accessible with a screwdriver.
TROLS: XL 883, XL 883L, XL 883R, XL 1200R for instal-
b. Fit nut hex into recess of outer ramp and turn adjust-
lation procedure.
ing screw counterclockwise until resistance is felt.
10. Open left side cover and remove Maxi-Fuse. Close left
Back off adjusting screw 1/4 turn.
side cover. See 7.25 MAXI-FUSE.
2006 Sportster: Drive/Transmission
6-9
HOME
PRIMARY DRIVE/CLUTCH
6.5
When the clutch is engaged (clutch lever released), the dia-
GENERAL
phragm spring (17) applies strong inward force against the
pressure plate (11). The pressure plate then presses the
The purpose of the clutch is to smoothly engage and disen-
clutch plates (8, 9, and 10) together, allowing no slippage
gage the engine from the rear wheel for starting, stopping,
between the plates and causing the plates to turn as a single
and shifting gears.
unit. The result is that the rotational force of the clutch shell is
fully transmitted through the “locked” clutch plates to the
See Figure 6-11. The clutch is a wet, multiple-disc unit with
clutch hub. As long as the transmission is set in a forward
one spring plate (8), six steel plates (9), and eight fiber (fric-
gear, power from the engine will be transmitted to the rear
tion) plates (10) stacked alternately in the clutch shell (2). The
wheel.
order of plate assembly, from inboard to outboard, is as fol-
lows:
When the clutch is disengaged (clutch lever pulled to left han-
dlebar grip), the pressure plate is pulled outward (by clutch
cable action) against the diaphragm spring, thereby com-
F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F
pressing the diaphragm spring. With the pressure plate
retracted, strong inward force no longer squeezes the clutch
plates together. The friction plates are now free to rotate at a
(F = Friction plate, St = Steel plate, Sp = Spring plate)
different relative speed than that of the steel and spring plates
(i.e. - slippage between the clutch plates occurs). The result
is that the rotational force of the clutch shell is no longer fully
The friction plates (clutch driving plates) are keyed to the
transmitted through the “unlocked” clutch plates to the clutch
clutch shell, which is driven by the engine through the primary
hub. The engine is free to rotate at a different speed than the
chain. The steel plates (clutch driven plates) and the centrally
rear wheel.
located spring plate (8) (also a clutch driven plate) are keyed
to the clutch hub (5), which drives the rear wheel through the
transmission and secondary drive belt.
Table 6-5. Clutch Troubleshooting
SYMPTOM
CAUSE (CHECK IN FOLLOWING ORDER)
REMEDY
Clutch slips.
Incorrect clutch release adjustment.
Check and adjust clutch release mechanism.
Worn clutch plates.
Check service wear limits. Replace plates.
Clutch drags
Incorrect clutch release adjustment.
Check and adjust clutch release mechanism.
Worn clutch release ramps or balls.
Replace release ramps and/or balls.
Warped clutch steel plates.
Replace clutch steel plates.
Blade worn or damaged clutch gear splines.
Replace clutch gear or hub as required.
Overfilled primary.
Drain lubricant to correct level.
6-10
2006 Sportster: Drive/Transmission
HOME
x0154b6x
2
3
4
5
6
7
1
8
9
10
11
12
13
14
28
18
19
20
15
21
22
23
16
24
25
17
26
27
1.
Retaining ring
15. Release plate
2.
Clutch shell and sprocket
16. Retaining ring
3.
Ball bearing
17. Diaphragm spring
4.
Retaining ring
18. Spring seat
5.
Clutch hub
19. Retaining ring
6.
Spring washer
20. Retaining ring
7.
Mainshaft nut
21. Inner ramp
8.
Spring plate
22. Outer ramp
9.
Steel plate (6)
23. Nut
10.
Friction plate, fiber (8)
24. Locking plate
11.
Pressure plate
25. Clutch adjustment spring
12.
Adjusting screw
26. Ball (3)
13.
Bearing
27. Clutch cable coupling
14.
Retaining ring
28. Clutch pack (consists of items 8, 9, 10)
Figure 6-11. Clutch Assembly
2006 Sportster: Drive/Transmission
6-11
HOME
REMOVAL
Table 6-6. Sprocket Locking Link
Applications
PART NO.
ENGINE
PART NO.
SPECIALTY TOOL
HD-38362
Domestic 883 cc
HD-38362 or
Sprocket locking link (for correct
HD-46283
application, refer to Table 6-6.)
HD-46283
HDI/Japan 883 cc and all 1200 cc
HD-34902-B
Bearing race remover and installer kit
11502
1WARNING
2
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect battery cables
(negative (-) cable first) before proceeding. (00307a)
NOTE
See Figure 6-11. If replacement of clutch pack (28) is the only
service work required, perform REMOVAL Steps 1 and 4
only, and then proceed to the NOTES under DISASSEMBLY.
1.
Disconnect negative
(-) battery cable from stud on
engine crankcase behind starter motor assembly. See
1
1.7 BATTERY MAINTENANCE.
1.
Sprocket locking link (Part No. HD-46283 or
2.
Open left side cover. No tools are required. See 1.6
HD-38362)
LEFT SIDE COVER.
2.
Shifter shaft
3.
Remove positive (+) battery cable from battery positive
(+) terminal. See 1.7 BATTERY MAINTENANCE.
Figure 6-12. Using Sprocket Locking Link
(Part No. HD-46283 or HD-38362) to
4.
Remove primary cover, as described under Primary
Loosen Engine Sprocket Nut
Cover REMOVAL under
6.3 PRIMARY CHAIN
ADJUSTER.
6. See Figure
6-11. Remove large retaining ring
(16).
Remove adjusting screw assembly (12, 13, 14 and 15)
CAUTION
from pressure plate (11).
See Figure 6-12. In the next step, you will be positioning
NOTE
the SPROCKET LOCKING LINK (1) on the engine and
Transmission mainshaft nut (7) has left-hand threads. Turn
clutch sprockets. Make sure you do not position the
nut clockwise to loosen and remove from mainshaft.
sprocket locking link too close to the shifter shaft (2). If
7. Remove nut (7) and spring washer (6). Remove the
the sprocket locking link contacts the shifter shaft while
clutch assembly, primary chain and engine sprocket as
you are exerting force to loosen the engine sprocket nut,
an assembly from the vehicle.
the sprocket locking link may damage the shifter shaft
and/or the engine crankcase.
8. Inspect primary chain. If damaged or excessively worn,
remove it from engine sprocket and clutch assembly;
NOTE
replace original primary chain with a new one.
For correct sprocket locking link application, refer to Table 6-
9. Inspect stator and rotor. See
7.12 ALTERNATOR.
6.
Replace damaged parts as necessary.
5.
See Figure 6-12. Install SPROCKET LOCKING LINK.
NOTE
Remove the engine sprocket nut. Loosen, but do not
If replacement of primary chain is the only service work
remove, engine sprocket. If necessary, use three items
required, proceed directly to INSTALLATION on page page 6-
from BEARING RACE REMOVER AND INSTALLER KIT:
16. Skip Step 1 and begin with the NOTE preceding Step 2.
END CAP (Part No. HD-34902-7), BRIDGE (Part No. J-
7830-5) and FORCING SCREW (Part No. J-21686-12),
and two bolts to loosen the engine sprocket.
6-12
2006 Sportster: Drive/Transmission
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