Harley Davidson 2008 Touring Models. Service Manual — page 6

1.10

TRANSMISSION LUBRICANT

TRANSMISSION LUBRICATION: TOURING
MODELS

General

The transmission lubricant level should be checked monthly.

Refer to

Table 1-1

. The transmission should be drained and

refilled with fresh lubricant at specified intervals.

NOTE

When checking the transmission lubricant level, the motorcycle
should be leaning on the jiffy stand. Allow a short period of
time to equalize lubricant level in the transmission compart-
ments.

Check Lubricant Level

Park motorcycle on its jiffy stand.

See

Figure 1-13

. Remove the threaded filler plug/dipstick.

See

Figure 1-14

. Wipe off filler plug/dipstick. Place in filler

hole and remove. (Dipstick should rest on lip of filler. Do
not screw in.) Lubricant level should be between the full
and low marks on the plug/dipstick when removed.

Be sure that no lubricants or fluids get on tires, wheels or
brakes when changing fluid. Traction can be adversely
affected, which could result in loss of control of the
motorcycle and death or serious injury. (00047d)

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

Add lubricant, if necessary. Do not overfill or leakage may
occur. When filling the transmission, use GENUINE Harley-
Davidson FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT (Part No. 99851-05 quart). The
transmission fluid capacity is approximately 32 fluid
ounces (0.95 liters).

Inspect o-ring for tears or damage. Replace if required.
Wipe any foreign material from plug.

Install threaded filler/check plug and tighten clockwise to
25-75 in-lbs (2.8-8.5 Nm).

pd00131

Figure 1-13. Transmission Filler Plug/Dipstick Location

sm05327

FULL

ADD

Figure 1-14. Transmission Filler Plug/Dipstick Lubricant

Level

Changing Transmission Fluid

See

Figure 1-13

. Remove the threaded filler plug/dipstick.

See

Figure 1-4

. Remove transmission drain plug from the

right side of the oil pan and drain lubricant into a suitable
container.

When draining or adding lubricant, do not allow dirt, debris
or other contaminants to enter the engine. (00198a)

2008 Touring Service: Maintenance 1-21

NOTE

Dispose of transmission lubricant in accordance with local
regulations.

Inspect o-ring for tears or damage on the drain plug.
Replace if required. Wipe any foreign material from plug.

Install drain plug and tighten to 14-21 ft-lbs (19.0-28.5
Nm). Fill the transmission with 32 fl. oz. (0.95 liters) of
GENUINE Harley-Davidson FORMULA+ TRANSMISSION

AND PRIMARY CHAINCASE LUBRICANT (Part No.
99851-05 quart).

NOTE

Do not overfill or leakage may occur. The transmission fluid
capacity is approximately 32 fl. oz. (0.95 liters).

Install threaded filler plug/dipstick and tighten clockwise
to 25-75 in-lbs (2.8-8.5 Nm).

Start engine and carefully check for oil leaks around drain
plug.

1-22 2008 Touring Service: Maintenance

1.11

CLUTCH

ADJUSTMENT

NOTE

Perform the clutch adjustment with the motorcycle at room
temperature. The clearance at the adjuster screw will increase
as the powertrain temperature increases. If adjuster screw is
adjusted with powertrain hot, clearance at push rod bearing
could be insufficient with powertrain cold and clutch slippage
could occur.

Stand motorcycle upright and level.

Remove five screws to free clutch inspection cover from
primary chaincase cover.

Remove seal ring from clutch inspection cover and discard.

See

Figure 1-15

. Add freeplay to cable.

Slide rubber boot off cable adjuster.

Holding cable adjuster with 1/2 in. wrench, loosen
jam nut using a 9/16 in. wrench. Back jam nut away
from cable adjuster.

Move adjuster toward jam nut to introduce a large
amount of free play at hand lever.

See

Figure 1-16

. Loosen jam nut on clutch adjuster screw.

To take up all free play, turn screw inward (clockwise) until
lightly seated.

Back out adjuster screw 1/2 to 1 full turn. While holding
adjuster screw with an allen wrench, tighten jam nut to 72-
120 in-lbs (8.1-13.6 Nm), while holding adjusting screw
with an Allen wrench.

Squeeze clutch lever to maximum limit three times to set
ball and ramp release mechanism.

Check freeplay.

Turn cable adjuster away from jam nut until slack is
eliminated at hand lever.

See

Figure 1-17

. Pull clutch cable ferrule away from

clutch 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 between end of cable ferrule and clutch
lever bracket.

Hold adjuster with 1/2 in. wrench. Using 9/16 in. wrench,
tighten jam nut against cable adjuster. Cover cable
adjuster mechanism with rubber boot.

10. Swab all lubricant from seal ring groove in clutch inspection

cover. Install new seal ring in groove with nubs contacting
ring groove walls.

11. Install five screws to fasten clutch inspection cover to

primary chaincase cover. Alternately tighten screws to 84-
108 in-lbs (9.5-12.2 Nm) in the sequence shown in

Figure 1-12

sm02219

Rubber boot

Cable adjuster

Jam nut

Cable end

Figure 1-15. Clutch Cable Adjuster

sm04769

Jam nut

Clutch adjuster screw

Figure 1-16. Clutch Adjuster Screw

2008 Touring Service: Maintenance 1-23

pd00059

Clutch cable

Cable ferrule

Clutch lever bracket

1/16-1/8 in. (1.6-3.2 mm)

Figure 1-17. Clutch Hand Lever

1-24 2008 Touring Service: Maintenance

sm02428

Screw (2)

Lockplate

Sprocket nut

Sprocket

Main drive gear

Figure 6-40. Transmission Sprocket

sm02430

Mainshaft locknut wrench

Rear fork pivot nut

Final drive sprocket locking tool

3/4 inch breaker bar

Figure 6-41. Sprocket Nut Removal (Typical)

CLEANING AND INSPECTION

Using a non-volatile cleaning solvent, clean sprocket of
all grease and dirt.

Inspect belt and sprocket. See

1.12 REAR BELT AND

SPROCKETS, Inspection

Inspect both main drive gear and mainshaft seals. Replace
if damaged.

INSTALLATION

TOOL NAME

PART NUMBER

FINAL DRIVE SPROCKET LOCKING
TOOL

HD-46282

MAINSHAFT LOCKNUT WRENCH

HD-47910

PILOT

HD-94660-2

NOTE

Only install sprocket nut while transmission is installed in frame.
Failure to do so will result in damage to transmission and/or
transmission stand.

Place transmission sprocket in position. Install the belt on
the sprocket as the sprocket is installed on the main drive
gear.

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-handed threads.
Turn the nut clockwise to install on the main drive gear.

See

Figure 6-40

. Install the sprocket nut. The following

procedure is based on whether a new or used nut is being
used.

New sprocket nut: spread a small quantity of clean
engine oil on the inside face of the sprocket nut and
the outside face of the sprocket. Limit the application
to where the surfaces of the two parts contact each
other. Install the sprocket nut until finger tight.

Used sprocket nut: apply Loctite High Strength
Threadlocker 271 (red) to the threads of the sprocket
nut. Also spread a small quantity of clean engine oil
on the inside face of the sprocket nut and the outside
face of the sprocket. Limit the application to where
the surfaces of the two parts contact each other.
Install the sprocket nut until finger tight.

See

Figure 6-42

. Lock transmission sprocket with the

FINAL DRIVE SPROCKET LOCKING TOOL (Part No. HD-
46282) (2). Final drive sprocket locking tool must rest
against upper portion of rear fork pivot nut (3).

Install PILOT (Part No. HD-94660-2) on mainshaft.

Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
47910) (1), tighten sprocket nut to 35 ft-lbs (47.5 Nm) initial
torque.

Loosen sprocket nut to remove initial torque.

Tighten sprocket nut to 35 ft-lbs (47.5 Nm).

Failure to use Main Drive Gear Remover and Installer can
cause premature failure of bearing and related parts.
(00540b)

See

Figure 6-43

. Scribe a line (3) on the transmission

sprocket nut (1). Continue the line on the transmission
sprocket (2) as shown.

Tighten the transmission sprocket nut an additional 35°
to 40°.

6-20 2008 Touring Service: Drive

10. Install lockplate over transmission sprocket nut so that two

of lockplate's four drilled holes (diagonally opposite) 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° of clock-
wise 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.

11. If holes in lockplate do not align with those in sprocket,

continue to tighten sprocket nut (up to the 45° maximum)
until sprocket and lockplate holes are in alignment.

NOTES

•

New screws have LOCTITE patches. With LOCTITE High
Strength Threadlocker 271 (red) reapplied before installa-
tion, the screws can be re-used up to three times.

•

To ensure the lockplate's security, BOTH screws must be
installed in the lockplate.

12. See

Figure 6-40

. Install two screws (1) to secure lockplate

(2) to sprocket (4).

13. Tighten screws to 84-108 in-lbs (9.5-12.2 Nm).

14. Install primary chain assembly. See

6.3 DRIVE COMPON-

ENTS

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.

15. Install primary chaincase cover and new gasket. See

6.2 PRIMARY CHAINCASE COVER

16. Fill primary chaincase with lubricant. See

1.9 PRIMARY

CHAIN

17. Verify pivot shaft torque. See

2.22 REAR FORK

18. Adjust belt tension. See

1.13 REAR BELT DEFLECTION

19. Verify vehicle alignment and tighten rear axle. See

2.11 VEHICLE ALIGNMENT

sm02435

Mainshaft locknut wrench

Final drive sprocket locking tool

Rear fork pivot nut

3/4 inch breaker bar

Figure 6-42. Sprocket Nut Installation (Typical)

30°

45°

sm05068

Transmission sprocket nut

Transmission sprocket

Scribed lines

Figure 6-43. Transmission Sprocket Nut Final Tightening

2008 Touring Service: Drive 6-21

1.12

REAR BELT AND SPROCKETS

GENERAL

When a drive belt is replaced for any reason other than stone
damage, it is recommended that the transmission and rear
sprockets also be replaced to increase the longevity of the new
drive belt. In the case of stone damage, inspect sprockets for
damage and replace as required.

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)

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets.
Clean the belt with a rag slightly dampened with a light cleaning
agent.

INSPECTION

Sprockets

NOTE

If chrome chips or gouges to rear sprocket are large enough
to be harmful, they will leave a pattern on the belt face.

See

Figure 1-18

. Inspect each tooth (1) of rear sprocket

for:

Major tooth damage.

Large chrome chips with sharp edges.

Gouges caused by hard objects.

Excessive loss of chrome plating (see next step).

To check if chrome plating has worn off, drag a scribe or
sharp knife point across the bottom of a groove (2)
(between two teeth) with medium pressure.

If scribe or knife point slides across groove without
digging in or leaving a visible mark, chrome plating
is still good.

If scribe or knife points digs in and leaves a visible
mark, it is cutting the bare aluminum. A knife point
will not penetrate the chrome plating.

Replace rear sprocket if major tooth damage or loss of
chrome exists.

sm02222

Tooth

Groove

Figure 1-18. Rear Sprocket

Rear Belt

See

Figure 1-19

. Inspect drive belt for:

•

Cuts or unusual wear patterns.

•

Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.

•

Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.

•

Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmission
sprocket.

•

Signs of puncture or cracking at the base of the belt teeth.
Replace belt if either condition exists.

•

Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.

2008 Touring Service: Maintenance 1-25

Stone

Belt cross-section

Sprocket side
of belt

sm01390

Figure 1-19. Drive Belt Wear Patterns

Table 1-9. Drive Belt Wear Analysis

REQUIRED ACTION

CONDITION

PATTERN

OK to run, but monitor condition.

Internal tooth cracks (hairline)

Replace belt.

External tooth cracks

Replace belt.

Missing teeth

OK to run, but monitor condition.

Chipping (not serious)

OK to run, but monitor condition.

Fuzzy edge cord

Replace belt and sprocket.

Hook wear

Replace belt if damage is on the edge.

Stone damage

OK to run, but monitor condition.

Bevel wear (outboard edge only)

Check idler bearings and bracket attachment.

Excess edge wear (XR only)

1-26 2008 Touring Service: Maintenance

1.13

REAR BELT DEFLECTION

CHECKING BELT DEFLECTION

TOOL NAME

PART NUMBER

BELT TENSION GAUGE

HD-35381A

Check rear belt deflection:

•

As part of pre-ride inspection.

•

At every scheduled service interval.

Check belt deflection:

•

With transmission in neutral.

•

At loosest spot in belt.

•

With motorcycle at ambient temperature.

•

With motorcycle upright and rear wheel in air or on jiffy
stand without rider or luggage.

Remove left side saddlebag.

See

Figure 1-20

. Obtain BELT TENSION GAUGE (Part

No. HD-35381A).

NOTE

Customers may purchase gauge from an authorized Harley-
Davidson dealer.

To use the belt tension gauge:

Slide O-ring toward 0 lbs (0 kg) mark.

Fit cradle against bottom of belt half way between
transmission and rear wheel compensator sprockets.
See

Figure 1-21

While observing belt deflection through the window
on the debris deflector, push upward on knob until O-
ring slides down to the 10 lbs (4.5 kg) mark.

NOTE

Next to the deflection window is a graduated scale. Each
graduation represents 1/8 in. (3.2 mm) of belt deflection.

Rotate rear wheel and measure deflection at different
spots on the belt. Compare results with specifications in

Table 1-10

If deflection is within specification, install left side
saddlebag.

If deflection is not within specification, see

1.13 REAR

BELT DEFLECTION, Setting Belt Deflection

NOTE

Always use BELT TENSION GAUGE (Part No. HD-35381A)
to measure belt deflection. Do not rely on "feel" as this can
result in belts that are under tensioned. Loose belts will fail due
to "ratcheting" (jumping a tooth) with resultant tensile cord
crimping and breakage.

Table 1-10. Belt Deflection

MILLIMETERS

INCHES

MODEL

9.5-11.1

3/8-7/16

FLHR/C
FLHT/C/U
FLTR

6.4-7.9

1/4-5/16

FLHX

sm04787

Cradle

0 lbs (0 kg) mark

O-ring

10 lbs (4.5 kg) mark

Knob

Figure 1-20. Belt Tension Gauge (Part No. HD-35381A)

om00156

Transmission sprocket

Rear wheel sprocket

10 lbs (4.5 kg) of force

Amount of deflection

Figure 1-21. Checking Belt Deflection

2008 Touring Service: Maintenance 1-27

SETTING BELT DEFLECTION

TOOL NAME

PART NUMBER

BELT TENSION GAUGE

HD-35381A

AXLE NUT TORQUE ADAPTER

HD-47925

Initial Set-up

Remove right side saddlebag.

Remove E-clip from groove at end of axle.

NOTE

The Axle Nut Torque Adapter simplifies the belt adjustment
procedure by allowing the cone nut to be loosened and
tightened without having to remove the right side muffler. The
tool also can be used to rotate the weld nut on the left side.

Loosen cone nut as follows:

Obtain breaker bar with 1/2 inch drive head and AXLE
NUT TORQUE ADAPTER (Part No. HD-47925).

Install torque adapter perpendicular to breaker bar.

Insert tool up between rear wheel and muffler to
capture cone nut. For best clearance with muffler, be
sure torque adapter is on the outboard side.

Rotate cone nut in a counter-clockwise direction until
loose.

Obtain torque wrench with 1/2 inch drive head and AXLE
NUT TORQUE ADAPTER (Part No. HD-47925). Proceed
as follows:

Install torque adapter perpendicular to torque wrench.
See upper frame of

Figure 1-22

Insert tool up between rear wheel and muffler to
capture cone nut. For best clearance with muffler, be
sure torque adapter is on the outboard side. See lower
frame of

Figure 1-22

NOTE

Since any extension can act as a torque multiplier, the
torque wrench must be perpendicular to the torque adapter
when the cone nut is tightened. The 90° orientation
between the tools cancels the multiplier effect and prevents
the cone nut from being over-tightened. If the torque
adapter is kept in-line with the torque wrench, the multiplier
effect is in force and parts damage will occur.

Verify that cam just contacts weld nub on both sides
of rear swingarm. If necessary, push wheel forward
slightly to achieve the desired result. See

Figure 1-23

Snug the cone nut to 15-20 ft-lbs (20-27 Nm).

Use BELT TENSION GAUGE (Part No. HD-35381A) to
check belt deflection. See

1.13 REAR BELT DEFLEC-

TION, Checking Belt Deflection

If belt is too loose, see Belt Too Loose.

If belt is too tight, see Belt Too Tight.

If belt deflection is within specification, see Reas-
sembly.

sm04528

Torque wrench

Axle nut torque adapter (HD-47925)