Harley Davidson 2005 touring models. Service repair manual — page 20
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NOTES
6-16
2005 Touring: Drive
HOME
PRIMARY CHAINCASE
6.5
GENERAL
The primary chaincase is a sealed housing containing the
primary chain, clutch, engine compensating sprocket, chain
tensioner assembly, alternator and starter drive mechanism.
Adjuster
LUBRICATION
Screw
See Section 1.7 PRIMARY CHAIN/LUBRICANT, PRIMARY
CHAIN LUBRICANT.
Locknut
REMOVAL
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
Release
Plate
Retaining
1WARNING
Ring
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
f1509b6x
2.
Unthread bolt and remove battery negative cable (black)
Figure 6-18. Clutch
Hub Release Plate Assembly
from battery negative (-) terminal.
3.
Standing on left side of motorcycle, remove magnetic
NOTE
drain plug at bottom of primary chaincase cover. Drain
lubricant into suitable container.
If drain plug has accumulated a lot of debris, inspect the con-
dition of chaincase components.
4.
Remove socket screw with lockwasher to remove pas-
f1840x6x
senger footboard from rear swingarm bracket.
Top Center Nut
5.
Remove socket screw (with lockwasher and flat washer)
to release front footboard forward bracket from frame
weldment. For best results, approach from opposite side
using a 3/8 inch ball allen with extension. To free front
footboard rear bracket from frame weldment and jiffy
Primary
stand bracket, remove lower hex bolt (with lockwasher)
Chain
and upper hex bolt (with lockwasher and locknut).
6.
Remove locknut, lockwasher and flat washer to free
shifter rod from front inboard shifter lever.
7.
Remove socket head screws and pull both toe and heel
shifter levers from shifter shaft. Remove rubber spacer. If
preferable, remove socket head screw to release front
inboard shifter lever instead, and then pull shifter shaft/
Adjuster
lever assembly from primary chaincase bore. When pull-
Shoe
ing any lever from splined shaft, always mark splines on
both shaft and lever to assist in assembly.
Figure 6-17. Chain Tensioner Assembly
2005 Touring: Drive
6-17
HOME
8.
Remove ten allen head socket screws (with captive
washers) from primary chaincase cover. Remove pri-
f1208axx
Alternator Rotor Spacer
mary chaincase cover from motorcycle.
Low Output Rotor Only - 0.020 In.
9.
Loosen top center nut from captured bolt of chain ten-
sioner assembly. See Figure 6-17. Lower the chain ten-
Compensating
sioner assembly as required, so that the adjuster shoe
Sprocket
rests flat on casting of primary chaincase.
Sprocket
Cover
1WARNING
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
Shaft
that the tips of the pliers are not damaged or excessively
Extension
worn. Slippage may propel the ring with enough force to
cause eye injury.
Sliding
10. Remove retaining ring and pull release plate (with lock-
Cam
nut and adjuster screw) from clutch hub. See Figure 6-
Compensating
Sprocket Nut
18.
11. Obtain the PRIMARY DRIVE LOCKING TOOL (HD-
41214). See Figure 6-19.
Figure 6-21. Engine Compensating Sprocket Assembly
With the flat side against the upper strand of the primary
chain, insert stepped side of tool into teeth of engine
compensating sprocket. Using a breaker bar and 1-1/2
direction. Once the stepped area of the tool is drawn into
inch socket, turn the sprocket nut in a counterclockwise
the sprocket, rotation of the primary drive is stopped.
Continue turning sprocket nut until loose. See Figure 6-
20.
NOTE
CAUTION
If too much loctite, or perhaps the wrong loctite, was used to
Do not place the tool on the
install the engine compensating sprocket nut, it may be very
lower strand of the primary
chain. Rotation of either the com-
difficult to remove. In these cases, break down loctite using
pensating sprocket nut or clutch
heat from a small propane torch. Apply heat evenly around
hub nut causes tool to exert
nut head in a circular motion, but not for so long as to turn nut
enough force to break or shatter
the nylon adjuster shoe.
blue. Do not direct heat at chain tensioner assembly and
other components or damage will result. If unable to loosen
sprocket nut with breaker bar after applying heat, use air
Figure 6-19. Primary Drive Locking Tool
impact wrench as the last alternative.
(Part No. HD-41214)
7859
7856
Primary Drive
Locking Tool
Primary Drive
Locking Tool
Breaker
Breaker
Bar
Bar
Figure 6-20. Place Primary Drive Locking Tool
Figure 6-22. Place Primary Drive Locking Tool
and Loosen Compensating Sprocket Nut
and Loosen Clutch Hub Mainshaft Nut
6-18
2005 Touring: Drive
HOME
18. From right side of motorcycle, remove starter front
7943
mounting screw with lockwasher. Remove rear mounting
Compensating
screw with lockwasher, but do not disconnect chassis
Sprocket
ground cable ring terminal.
19. Returning to left side of motorcycle, remove two bolts
(with flat washers) from outside edge of primary chain-
case.
20. Using a chisel and hammer, bend tabs on lockplates
Primary
away from heads of 5 inside bolts. Remove bolts (with
Chain
lockplates) to free primary chaincase from crankcase
and transmission housings. Remove primary chaincase
from motorcycle.
Shaft
21. Remove O-ring from crankcase lip and discard.
Extension
Clutch
Assembly
Figure 6-23. Remove Clutch Assembly, Primary Chain,
INSPECTION AND REPAIR
Compensating Sprocket and Shaft Extension
1.
Inspect the primary chaincase for cracks or other dam-
age. Replace as necessary.
1WARNING
2.
Check the mainshaft bearing. Bearing must rotate freely
Use extreme caution when operating propane torch.
without drag. Replace the bearing if necessary. Replace
Read the manufacturers instructions carefully before
the lip seal. See MAINSHAFT BEARING AND LIP SEAL
use. Do not direct open flame or heat toward any fuel
on this page.
system component. Extreme heat can cause fuel ignition
NOTE
and explosion. Inadequate safety precautions could
Also check the bearing inner race on the mainshaft. Replace
result in death or serious injury.
the race if scored or excessively worn. See MAINSHAFT
12. Reverse the position of the primary drive locking tool.
BEARING INNER RACE in this section.
With the flat side against the upper strand of the primary
3.
Check the starter jackshaft bushing in the primary chain-
chain, insert stepped side of tool into teeth of clutch
case. Check the jackshaft bushing in the primary chain-
sprocket. Using a breaker bar and 1-3/16 inch socket,
case cover. Replace the bushings if they are damaged
turn the clutch hub mainshaft nut in a clockwise direction
or excessively worn (i.e., through the teflon and copper
until loose. See Figure 6-22.
coatings into the steel backing). Replace the lip seal.
NOTE
See STARTER JACKSHAFT BUSHING AND LIP SEAL
- PRIMARY CHAINCASE in this section.
Clutch hub mainshaft nut has left handed threads.
4.
Check the shifter bracket bushings in the primary chain-
13. Remove the primary drive locking tool. Remove the
case. Replace the bushings if necessary. See SHIFTER
clutch hub mainshaft nut and engine compensating
BRACKET BUSHINGS in this section.
sprocket nut.
14. Remove sprocket cover and sliding cam. See Figure 6-
21.
15. Remove clutch, primary chain, compensating sprocket
DISASSEMBLY
and shaft extension as a single assembly. See Figure 6-
23.
MAINSHAFT BEARING AND LIP SEAL
16. Remove the alternator rotor spacer from the engine
sprocket shaft, if present.
REMOVAL
NOTE
The alternator rotor spacer is only present on those vehicles
1WARNING
with the 38 amp low output rotor.
Always wear proper eye protection when removing re-
17. Bend tab on lockplate away from head of jackshaft bolt.
taining rings. Use the correct retaining ring pliers. Verify
Holding pinion gear to prevent rotation, remove the jack-
that the tips of the pliers are not damaged or excessively
shaft bolt with lockplate and thrust washer. Carefully pull
worn. Slippage may propel the ring with enough force to
jackshaft assembly from primary chaincase bore.
cause eye injury.
2005 Touring: Drive
6-19
HOME
1.
Remove retaining ring from groove on clutch side of pri-
f1216x6x
mary chaincase. Turn the chaincase over to transmis-
sion side.
2.
Pull lip seal from bearing bore on transmission side of
primary chaincase. Use a seal remover or rolling head
pry bar for best results. Remove retaining ring from
groove on same side of chaincase.
CAUTION
Failure to provide proper support will cause the casting
to crack or break around the outside diameter of the
boss. Any damage to the casting requires replacement
of the primary chaincase.
3.
Place primary chaincase in arbor press with the trans-
Figure 6-24. Mainshaft Bearing Inner Race Remover
mission side up. Be sure to properly support boss on
(Part No. HD-34902B)
clutch side to avoid damage to casting.
4.
Center bearing under ram, and using a suitable driver,
f1217x7x
carefully press out bearing applying pressure to the
outer race.
INSTALLATION
1. Inspect the bearing bore to verify that it is clean and
Bearing
smooth.
Inner Race
Mainshaft
1WARNING
Plug
Always wear proper eye protection when installing re-
Bridge
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
2. Install retaining ring in groove on transmission side of
primary chaincase. Verify that the retaining ring is fully
Puller
Long
seated in the groove.
Plate
Bolt
Flat
3. Apply a thin film of clean H-D 20W50 engine oil to bear-
Washer
ing bore and O.D. of new bearing.
Forcing
CAUTION
Screw
Failure to provide proper support will cause the casting
Figure 6-25. Pull Mainshaft Bearing Inner Race
to crack or break around the outside diameter of the
boss. Any damage to the casting requires replacement
of the primary chaincase.
8.
Lubricate O.D. of new lip seal with clean H-D 20W50
4.
Place primary chaincase in arbor press with the clutch
engine oil. With the lip garter spring side (also stamped
side up. Be sure to properly support boss on transmis-
“OIL SIDE”) facing the bearing, press lip seal into bore
sion side to avoid damage to casting.
until outer edge is flush with machined surface of the
5. Place bearing over bore with the lettered side up. Center
casting. To avoid seal damage, be sure to use a suitable
bearing under ram, and using a suitable driver, apply
driver that presses squarely on the outer edge of the
pressure to the outer race until bearing makes contact
seal carrier.
with the installed retaining ring.
9.
Verify that lip seal is square in the bore and completely
6.
Install second retaining ring to lock position of bearing in
seated around its circumference.
bore on clutch side of chaincase. Verify that retaining
ring is fully seated in the groove.
10.
Lubricate the bearing and lip seal with multi-purpose
grease or clean H-D 20W50 engine oil.
7.
Turn chaincase over, so that the transmission side is up.
6-20
2005 Touring: Drive
HOME
MAINSHAFT BEARING INNER RACE
f1215x6x
NOTE
The bearing inner race must be properly positioned on the
mainshaft to 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-34902B. See Figure 6-
24 and Figure 6-26.
REMOVAL
Figure 6-26. Mainshaft Bearing Inner Race Installer
1. Install small flat washers on two long bolts of puller tool.
(Part No. HD-34902B)
Slide one bolt into channel on each side of bridge so that
washer is between bridge and bolt head. Thread bolts
into stamped side of U-shaped puller plate an equal
number of turns.
Install Inner Race
and Extension Shaft
2. Sparingly apply graphite lubricant to threads of forcing
screw to ensure smooth operation. Thread forcing screw
into center hole of bridge.
3. Position U-shaped puller plate between bearing inner
race and sprocket nut. See Figure 6-25.
Extension
Shaft
4. Install mainshaft plug into end of transmission main-
shaft. Thread the forcing screw into the bridge until the
steel ball at the end of the screw seats in the cavity of
the mainshaft plug. Verify that the tool assembly is
square so that the bearing is not cocked during removal.
Wrench
5. Continue turning the forcing screw until the bearing inner
Flat
race is pulled free of the mainshaft.
Bearing
INSTALLATION
Inner Race
1. Chamfered edge first, slide the bearing inner race onto
the transmission mainshaft.
2. Thread extension shaft onto end of mainshaft. See
upper frame of Figure 6-27.
Install Tube, Flat Washers
and Hex Nut
NOTE
Extension shaft has left handed threads, so turn counter-
clockwise to install.
3. Slide installer tube over extension shaft until it contacts
bearing inner race. Sparingly apply graphite lubricant to
threads of extension shaft to ensure smooth operation.
4. Place both large flat washers over threaded portion of
Flat
extension shaft until they contact installer tube. Install
Washers
large hex nut onto extension shaft. See lower frame of
Figure 6-27.
5. With a wrench on flats at threaded end of extension
shaft, hold shaft stationary while turning hex nut in a
clockwise direction. In this manner, press race onto shaft
so inside edge is 0.100 in. (2.54 mm) from main drive
Installer
Tube
gear.
Hex
f1218x7x
6. Lubricate the race with multi-purpose grease or clean
Nut
engine oil.
Figure 6-27. Press Bearing Inner Race onto Mainshaft
2005 Touring: Drive
6-21
HOME
STARTER JACKSHAFT BUSHING
f1212a6x
Press Bushing Flush
AND LIP SEAL - PRIMARY CHAINCASE
With Boss or to a
Maximum Depth of
Bushing
REMOVAL
Primary
0.010 In. (0.25 mm)
Chaincase
1.
Remove bushing from jackshaft bore of primary chain-
case. For best results, use a bushing/bearing puller with
expandable collet and slide hammer.
2.
Remove lip seal from bore.
INSTALLATION
1.
Inspect the bushing bore to verify that it is clean and
Lip Seal
smooth. Place primary chaincase in arbor press with the
clutch side up. Support forward part of case so that it lies
flat on transmission mounting flanges.
Press Lip Seal
Transmission
Against Shoulder
2.
Lightly apply Loctite RETAINING COMPOUND No. 609
Side
to O.D. of new lip seal. With the open (lip garter spring)
side facing up, press fit lip seal into the jackshaft bore
Figure 6-28. Install Jackshaft Seal and Bushing in
until it makes solid contact with the shoulder on the
Primary Chaincase
transmission side. Verify that seal is square in the bore
and completely seated around its circumference.
3.
See Figure 6-28. Press new bushing into bore. Bushing
must be flush with boss or at a depth not exceeding
SHIFTER BRACKET BUSHINGS
0.010 in. (0.76 mm).
REMOVAL
4.
Lubricate the bushing and seal lip with multi-purpose
grease or clean engine oil.
1.
Remove spacer and shifter shaft assembly from shifter
bracket bore of primary chaincase.
2.
Using an arbor press, press bushings from bore. Inspect
STARTER JACKSHAFT BUSHING -
the bushing bore to verify that it is clean and smooth.
PRIMARY CHAINCASE COVER
REMOVAL
INSTALLATION
1.
Remove bushing from jackshaft bore of primary chain-
1.
Place primary chaincase in arbor press.
case cover. For best results, use a bushing/bearing
puller with expandable collet and slide hammer.
2.
Press new bushing into each end of bore. Installed
bushings must be flush to 0.010 inch (0.76 mm) above
2.
Inspect the bushing bore to verify that it is clean and
outer edge of bore.
smooth.
3.
Install shifter shaft in shifter bracket bore. Install spacer
on shifter shaft.
INSTALLATION
4.
Assemble primary chaincase. See Section
6.5 PRI-
1.
Using a T27 TORX drive head, remove five screws (with
MARY CHAINCASE, INSTALLATION, on the next page.
captive washers) to free clutch inspection cover from pri-
mary chaincase cover.
2.
Place primary chaincase cover in arbor press. Support
forward part of case so that it lies flat around the clutch
inspection cover bore.
3.
Press new bushing into bore. Bushing must be flush with
boss or at a depth not exceeding 0.010 in. (0.76 mm).
4.
Lubricate the bushing with multi-purpose grease or
clean engine oil.
6-22
2005 Touring: Drive
HOME
8
f2300x6x
11
9
10
18
9
12
17
13
14
21
2
5
3
20
3
4
16
5
25
26
5
25
19
7
14
6
6
1.
Magnetic drain plug and O-ring
2.
Primary chaincase cover
3.
Bolt (3), 5/16-18 x 3 in.
1
24
4.
Hole
19
5.
Lockplate (5)
22
6.
Bolt (4), 5/16-18 x 1-3/4 in.
23
7.
Primary chaincase
15
8.
Lip seal
9.
Retaining ring (2)
15. Primary chain inspection cover
21. Screw, cover (5)
10.
Bearing, mainshaft
16. Gasket
22. Gasket
11.
Lip seal
17. O-ring
23. Screw (4)
12.
Bushing
18. Dowel pin (2)
24. Screw (5)
13.
Bushing
19. Gasket
25. Washer (2)
14.
Bushing (2)
20. Screw, cover (5)
26. Clutch inspection cover
Figure 6-29. Primary Chaincase Assembly
2.
Verify cleanliness of all blind holes in both the crankcase
INSTALLATION
and transmission. Also verify that the mating surfaces of
the primary chaincase and crankcase/transmission
1. Install new O-ring on lip of crankcase.
interface are clean.
CAUTION
CAUTION
Avoid the use of sealant where the primary chaincase
The mainshaft splines may damage the sealing surface
mates with the crankcase/transmission interface. Use of
of the lip seal if the protector sleeve is not used.
sealant can actually interfere with the mating of these
parts. Never use sealant on the fasteners or case
3.
Place the seal protector sleeve (from the MAIN DRIVE
threads. The presence of sealant (loctite, dirt, water or
GEAR SEAL INSTALLER, HD-41405) over the main-
oil) in the blind holes of the crankcase or transmission
shaft splines. Lightly lubricate the sleeve with clean
can cause the castings to crack or break.
engine oil.
4.
Place the primary chaincase into position against the
NOTE
crankcase and transmission housings. Remove the seal
If the use of sealant is absolutely necessary to eliminate oil
protector sleeve from the mainshaft.
wicking past the primary chaincase mounting bolts, use only
5.
See A in left frame of Figure 6-30. Start two bolts (1-3/4
a light film around the bolt holes on the mating surfaces. With
inches with flat washers) to fasten outside edge of pri-
one exception, remember that all bolts go into blind holes.
mary chaincase to front of crankcase.
The only open hole is located at the bottom of the transmis-
sion case. See right frame of Figure 6-30.
2005 Touring: Drive
6-23
HOME
Start four 1-3/4 inch bolts to engine.
Start three 3 inch bolts to transmission.
7948
3
2
With Lockplate
With Lockplate
A
With Flat Washer
7
With Lockplate
5
B
4
Only Open Hole
6
1
7946
Figure 6-30. Primary Chaincase Screw Size and Torque Sequence
See B in left frame of Figure 6-30. From within the pri-
8. Install alternator rotor spacer on engine sprocket shaft, if
mary chaincase, start two bolts (1-3/4 inches with lock-
present. See Figure 6-21.
plates) to fasten primary chaincase to rear of crankcase.
NOTE
See right frame of Figure 6-30. From within the primary
The alternator rotor spacer is only present on those vehicles
chaincase, start three bolts (3 inches with lockplates) to
with the 38 amp low output rotor.
fasten primary chaincase to front and rear of transmis-
sion.
9. Install the clutch, primary chain, compensating sprocket
and shaft extension as a single assembly. See Figure 6-
Tighten the seven bolts to 18-21 ft-lbs (24-28 Nm) in the
23. Start clutch assembly on the mainshaft, while plac-
numerical sequence shown in Figure 6-30.
ing the shaft extension on the engine sprocket shaft. The
clutch hub and shaft extension are splined, so a slight
Bend one tab on each lockplate against the flat of the
rotation of the chain drive will aid in lining up the splines.
bolt head to secure.
10. Place sliding cam over shaft extension. Slide sprocket
6.
On right side of motorcycle, install the front starter
cover over sliding cam. See Figure 6-21.
mounting screw with lockwasher. Install rear mounting
11. Apply two drops of Loctite High Strength Threadlocker
screw and lockwasher (with chassis ground cable ring
262 (red) to the threads of the engine compensating
terminal). Alternately tighten front and rear starter
sprocket nut. Install nut and hand tighten in a clockwise
mounting screws to 14-18 ft-lbs (19-24 Nm).
direction.
7.
Returning to left side of motorcycle, gently insert jack-
12. Apply two drops of Loctite High Strength Threadlocker
shaft assembly into primary chaincase so that splined
262 (red) to the threads of the clutch hub mainshaft nut.
end of shaft engages coupling on starter output shaft.
Install nut and hand tighten in a counterclockwise
Insert key on lockplate through slot in thrust washer and
direction.
into keyway on jackshaft. Thread the jackshaft bolt into
the starter shaft making sure that the lockplate key
NOTE
remains in the keyway. Holding pinion gear to prevent
Clutch hub mainshaft nut has left handed threads.
rotation, tighten jackshaft bolt to 60-80 in-lbs (6.8-9.0
Nm). Bend tab on lockplate against flat of bolt head to
13. Obtain the PRIMARY DRIVE LOCKING TOOL (HD-
secure.
41214). See Figure 6-31.
6-24
2005 Touring: Drive
HOME
With the flat side against the upper strand of the primary
chain, insert stepped side of tool into teeth of clutch
1WARNING
sprocket. Verify that adjuster shoe of chain tensioner
Always wear proper eye protection when installing re-
assembly rests flat on casting of primary chaincase, and
then using a torque wrench and 1-1/2 inch socket,
taining rings. Use the correct retaining ring pliers. Verify
tighten sprocket nut to 150-165 ft-lbs (203-224 Nm). See
that the tips of the pliers are not damaged or excessively
Figure 6-32.
worn. Slippage may propel the ring with enough force to
cause eye injury.
NOTE
17.
Install retaining ring in clutch hub bore to lock release
Once the stepped area of the tool is drawn into the sprocket,
plate in position. Verify that the retaining ring is com-
rotation of the primary drive is stopped.
pletely seated in the groove.
14.
Reverse the position of the primary drive locking tool.
18.
Adjust clutch. See Section
6.3 CLUTCH, ADJUST-
With the flat side against the upper strand of the primary
chain, insert stepped side of tool into teeth of engine
MENT, steps 3-8.
compensating sprocket. Using a torque wrench and 1-3/
19.
Adjust primary chain tension. See Section 6.2 PRIMARY
16 inch socket, tighten clutch hub mainshaft nut to 70-80
CHAIN AND SPROCKETS, PRIMARY CHAIN ADJUST-
ft-lbs (95-108 Nm). See Figure 6-33.
MENT, steps 2-4.
15.
Remove the primary drive locking tool.
20.
Remove old gasket from flange of primary chaincase
16.
Install release plate (with locknut and adjuster screw)
and discard. Thoroughly clean gasket surface. Hang
into clutch hub bore. The word “OUT” is stamped on the
new gasket on dowels.
release plate to indicate the outboard side.
21.
Start ten allen head socket screws (five long, five short)
with flat washers to install primary chaincase cover.
Tighten screws to
84-108 in-lbs
(10-12 Nm) in the
numerical sequence shown in Figure 6-34.
CAUTION
Do not place the tool on the
22.
Clean magnetic drain plug and inspect O-ring for cuts,
lower strand of the primary
tears or signs of deterioration. Replace O-ring as neces-
chain. Rotation of either the com-
sary. Install drain plug back into primary chaincase cover
pensating sprocket nut or clutch
hub nut causes tool to exert
and tighten to 36-60 in-lbs (4.1-6.8 Nm).
enough force to break or shatter
the nylon adjuster shoe.
23.
Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from pri-
Figure 6-31. Primary Drive Locking Tool
mary chaincase cover, if installed.
(Part No. HD-41214)
Primary Drive
Primary Drive
Locking Tool
Locking Tool
Torque
Torque
Wrench
Wrench
7857
7858
Figure 6-32. Place Primary Drive Locking Tool
Figure 6-33. Place Primary Drive Locking Tool
and Torque Compensating Sprocket Nut
and Torque Clutch Hub Mainshaft Nut
2005 Touring: Drive
6-25
HOME
S = Short Screw, 1-1/4 In.
f1210x6x
1WARNING
L = Long Screw, 1-1/2 In.
S
Be sure that lubricant does not contact rear wheel, tire
and brake components. Such contact can adversely
L
8
L
affect traction and may lead to loss of vehicle control,
2
which could result in death or serious injury.
S
10
S
24.
Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY
4
6
CHAINCASE LUBRICANT through the clutch inspection
cover opening, Part No. 99887-84 (quart) or Part No.
99886-84 (gallon). See Figure 6-35.
Clutch
Inspection
25.
To avoid punching holes in the clutch inspection cover
Primary
Cover
Chain
gasket or enlarging existing holes, install clutch inspec-
Inspection
Cover
tion cover and new gasket as follows:
a. Align the triangular shaped hole in the gasket with
9
the top hole in the clutch inspection cover. Be sure
the rubber molding and the words “towards clutch”
5
L
Drain
7
face the motorcycle.
3
1
Plug
S
L
b. Insert screw (with captive washer) through clutch
S
L
inspection cover and carefully thread it all the way
through triangular shaped hole in gasket. Do not
Figure 6-34. Primary Chaincase Cover Torque Sequence
push screw through hole.
and Screw Size
c. Hang the clutch inspection cover on the primary
chaincase cover flange by starting the top cover
Primary
screw.
Chaincase Cover
d. Start the remaining four screws (with captive wash-
ers).
e. Using a T27 TORX drive head, alternately tighten
screws to 84-108 in-lbs (10-12 Nm) in the pattern
shown in Figure 6-36.
f1210x6x
Lubricant
1
4
3
f2301x6x
2
5
Figure 6-35. Fill Primary Chaincase With Lubricant
CAUTION
Do not overfill the primary chaincase with lubricant.
Overfilling may cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
Figure 6-36. Clutch Inspection Cover Torque Sequence
finding neutral at engine idle.
6-26
2005 Touring: Drive
HOME
26.
If installing toe and heel shifter levers, perform steps
29.
Install left side footboard and bracket assembly as fol-
26(a) thru
26(d). If just installing front inboard shifter
lows:
lever, perform steps 26(c) and 26(d).
a. Insert socket screw
(with lockwasher and flat
washer) through frame weldment into front foot-
a. Install rubber spacer onto end of shifter shaft.
board forward bracket. For best results, approach
b. Set the shifter levers down, so that the Harley-
from opposite side of motorcycle using a 3/8 inch
Davidson script on the rubber peg is topside. Now
ball allen with extension.
look at the socket head screw hole. If the hole is
b. At front footboard rear bracket, slide upper hex bolt
countersunk at the bottom, then it is the inboard
through frame weldment, jiffy stand bracket and
shifter lever (toe). If the hole is countersunk at the
footboard bracket thru hole. Install lockwasher and
top, it is the outboard shifter lever (heel).
locknut. Slide lower hex bolt through frame weld-
ment and jiffy stand bracket into threaded hole of
c. Install lever(s) onto splined shaft taking note to align
footboard bracket.
marks placed on splines during disassembly.
c. Tighten front bracket socket screw to 30-35 ft-lbs
d. Install socket head screw(s) to fasten lever(s) to
(41-48 Nm).
shaft. Tighten
1/4 inch screws to
90-110 in-lbs
(10.2-12.4 Nm) or 5/16 inch screws to 18-22 ft-lbs
d. Alternately tighten rear bracket hex bolts to 15-20 ft-
(24-30 Nm).
lbs (20-27 Nm).
30.
Insert bolt through battery negative cable (black) into
27.
Install flat washer, lockwasher and locknut to fasten
threaded hole of battery negative (-) terminal. Tighten
shifter rod to front inboard shifter lever.
bolt to 60-96 in-lbs (6.8-10.9 Nm).
28.
Install socket screw with lockwasher to fasten passenger
31.
Install seat. See Section 2.24 SEAT, INSTALLATION.
footboard to rear swingarm bracket. Tighten screw to 15-
18 ft-lbs (20-24 Nm). Repeat step on opposite side of
motorcycle.
2005 Touring: Drive
6-27
HOME
NOTES
6-28
2005 Touring: Drive
Table Of Contents
SUBJECT
PAGE NO.
7.1 Specifications
7-1
7.2 Transmission Power Flow
7-3
7.3 Shifter Linkage
7-5
7.4 Shifter Cam Assembly/Shifter Forks
7-6
7.5 Clutch Release Cover
7-12
7.6 Mainshaft/Countershaft
7-15
7.7 Main Drive Gear/Bearing
7-23
7.8 Transmission Case/Oil Pan
7-31
TRANSMISSION
7
HOME
SPECIFICATIONS
7.1
TRANSMISSION DATA
SERVICE WEAR LIMITS
TRANSMISSION
DATA
SHIFTER FORKS
IN.
MM
5-speed forward -
Shifter fork to cam
Type
0.0017-0.0019
0.043-0.048
constant mesh
groove end play
Quart
Part No. 99892-84
Shifter fork to gear
0.0010-0.0110
0.025-0.279
Semi-synthetic
groove end play
Case of Quarts
Part No. 98853-96
transmission
Gallon
Part No. 99891-84
lubricant
Case of Gallons
Part No. 98852-96
SHIFTER DOG
MINIMUM
MAXIMUM
24 oz.
GEARS
CLEARANCE
CLEARANCE
Capacity (dry)
710 ml
0.035 in.
0.139 in.
2nd-5th
Approximately
0.89 mm
3.53 mm
20-24 oz.
Capacity (wet)
0.035 in.
0.164 in.
590-710 ml
2nd-3rd
0.89 mm
4.17 mm
0.035 in.
0.152 in.
1st-4th
Internal Gear Ratios
0.89 mm
3.86 mm
GEAR
(Domestic, HDI and Swiss)
0.035 in.
0.157 in.
1st-3rd
First
3.21
0.89 mm
3.99 mm
Second
2.21
Third
1.57
MAINSHAFT
Fourth
1.23
IN.
MM
TOLERANCE
Fifth
1.00
Mainshaft runout
0.000-0.003
0.000-0.08
Mainshaft end play
none
none
ENGINE OIL
DATA
1st gear clearance
0.0000-0.0080
0.000-0.203
2nd gear clearance
0.0000-0.0800
0.000-2.032
4 quarts
Capacity (dry)
3rd gear end play
0.0050-0.0420
0.127-1.067
3.8 liters
3rd gear clearance
0.0003-0.0019
0.008-0.048
Approximately
Capacity (wet)
3-1/2 quarts
4th gear end play
0.0050-0.0310
0.127-0.787
3.3 liters
4th gear clearance
0.0003-0.0019
0.008-0.048
CAUTION
MAIN DRIVE
IN.
MM
A bent jiffy stand, modified suspension or uneven park-
GEAR (5TH)
ing area can cause dipstick to indicate a false low oil
Bearing fit in
condition.
transmission case
0.0003-0.0017
0.008-0.043
NOTE
(loose)
Since a sidecar equipped motorcycle is fixed in an upright
Fit on mainshaft
0.0001-0.0009
0.0025-0.023
position, the actual full engine oil level is about 1/2 inch (12.7
mm) above the FULL mark on the dipstick.
End play
none
none
Fit in side door (tight)
0.0014-0.0001
0.036-0.0025
2005 Touring: Transmission
7-1
HOME
SERVICE WEAR LIMITS (CONT.’D)
TORQUE VALUES
COUNTERSHAFT
IN.
MM
TOLERANCE
Item
ft/in-lbs
Nm
Countershaft runout
0.000-0.003
0.00-0.08
Shifter linkage rod
80-120 in-lbs
9.0-13.6 Nm
locknuts
Countershaft end play
none
none
Detent arm pivot screw
1st gear clearance
0.0003-0.0019
0.008-0.048
84-108 in-lbs
9.5-12.2 Nm
to right support block
1st gear end play
0.0050-0.0039
0.127-0.099
Shifter cam support
84-108 in-lbs
9-12 Nm
block screws
2nd gear clearance
0.0003-0.0019
0.008-0.048
Transmission top cover
84-132 in-lbs
9.5-14.9 Nm
2nd gear end play
0.0050-0.0440
0.127-1.118
socket head screws
3rd gear clearance
0.0000-0.0080
0.000-0.203
Neutral switch
120-180 in-lbs
13.6-20.3 Nm
4th gear clearance
0.0000-0.0080
0.000-0.203
Clutch release cover
84-132 in-lbs
9.5-14.9 Nm
socket head screws
4th gear end play
0.0050-0.0390
0.127-0.991
Clutch cable fitting
36-60 in-lbs
4-7 Nm
5th gear clearance
0.0000-0.0080
0.000-0.203
Transmission lubricant
14-21 ft-lbs
19-28 Nm
drain plug
5th gear end play
0.0050-0.0040
0.127-0.102
Transmission filler
25-75 in-lbs
2.8-8.5 Nm
plug/dipstick
Transmission side door
5/16 inch screws
13-18 ft-lbs
17.6-24.4 Nm
1/4 inch screws
84-132 in-lbs
9.5-14.9 Nm
Mainshaft/countershaft
45-55 ft-lbs
61-75 Nm
locknuts
Transmission mainshaft
60 ft-lbs, then
81 Nm, then
sprocket nut
35° to 45°
35° to 45°
Transmission sprocket
84-108 in-lbs
9-12 Nm
nut lockplate screws
Oil pan screws
84-132 in-lbs
9.5-14.9 Nm
Transmission-to-engine
15 ft-lbs,
20.3 Nm,
then
then
mounting bolts
30-35 ft-lbs
40.7-47.5 Nm
Oil hose cover
84-108 in-lbs
10-12 Nm
Rear swingarm
34-42 ft-lbs
46-57 Nm
bracket bolts
Rear swingarm
40-45 ft-lbs
54-61 Nm
pivot shaft locknut
Shifter lever to shifter
18-22 ft-lbs
24-30 Nm
shaft socket head screw
Engine oil drain plug
14-21 ft-lbs
19-28 Nm
Oil filler spout allen head
84-132 in-lbs
9.5-14.9 Nm
socket screws
7-2
2005 Touring: Transmission
HOME
TRANSMISSION POWER FLOW
7.2
GENERAL
4th Gear
The shift into fourth is made when mainshaft 2nd is disen-
See Figure 7-1. The 5-speed transmission consists of two
gaged from mainshaft 3rd and mainshaft 1st engages main-
parallel shafts supporting five gears each. The longer, or
shaft 4th, locking it to the mainshaft.
mainshaft, also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft.
5th Gear
Each gear on the mainshaft is in constant mesh with a corre-
The shift from fourth to fifth gear occurs when mainshaft 1st
sponding gear on the countershaft. Each of these five pairs
is shifted out of mainshaft 4th, and mainshaft 2nd is shifted
of gears makes up a different speed in the transmission.
directly into the main drive gear. Mainshaft 2nd lock the main
drive gear to the mainshaft resulting in a direct one-to-one
The transmission gears are divided into two types, gears that
drive ratio from the clutch to the sprocket.
are splined and rotate with the shaft, and freewheeling gears
that ride on bearings and spin freely on the shaft. A splined
gear always meshes with a freewheeling gear. Also, three of
the splined gears are able to slide sideways on the shaft.
These sliding gears are used to change transmission
speeds. The projections (or dogs) on the sides of the sliding
gears, engage dogs on adjacent freewheeling gears, trans-
mitting power through the transmission.
Gear shifting is accomplished by three forks which fit into
grooves machined into the hubs of the three sliding gears.
The position of the shifter forks is controlled by a drum-
shaped shifter cam located on the top of the transmission.
Neutral
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft 1st and 2nd
gears are rotating, but no power is transferred to the counter-
shaft since countershaft 1st and 2nd are freewheeling gears.
1st Gear
When the transmission is shifted into first gear, countershaft
3rd, which rotates with the countershaft, engages counter-
shaft 1st, which has been spinning freely on the countershaft
driven by mainshaft 1st.
Now countershaft 3rd is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft
5th to turn. Countershaft 5th transmits the power to the main
drive gear and the sprocket.
2nd Gear
Second gear is engaged when countershaft 3rd is shifted out
of countershaft 1st and engages countershaft 2nd. This locks
countershaft 2nd to the countershaft to complete the power
flow as shown.
3rd Gear
Two shifter forks are used to make the shift from second to
third. One fork moves countershaft 3rd out of countershaft
2nd to its neutral position, while another fork engages main-
shaft 2nd with mainshaft 3rd. This locks mainshaft 3rd to the
mainshaft to complete the power flow as shown.
2005 Touring: Transmission
7-3
HOME
Neutral
1st Gear
Countershaft
Out
In
1
1
2
2
3
3
5
4
5
4
Mainshaft
3rd Gear
2nd Gear
Out
In
1
1
In
2
3
3
5
2
4
5
4
5th Gear
4th Gear
Out
In
In
Out
3
1
4
3
1
4
5
2
5
2
Sliding Member
Power Flow
Figure 7-1. Transmission Power Flow Schematic
7-4
2005 Touring: Transmission
HOME
SHIFTER LINKAGE
7.3
ADJUSTMENT
9440
Rod
If operating problems exist, check the shifter linkage for wear,
interference or adjustment. If adjustment is necessary, see
SHIFTER LINKAGE below. If problems persist, see the
checks under Section 1.21 TROUBLESHOOTING, TRANS-
MISSION, along with the repair procedures in this section.
Locknut
Locknut
Shifter Linkage
The shifter linkage is set at the factory and should not need
adjustment under normal circumstances. However, if full
engagement or full lever travel is not achieved, adjust the
linkage rod as follows:
Figure 7-2. Shifter Linkage Adjustment
CAUTION
To ensure proper gear engagement and avoid possible
damage to transmission, the shifter lever should not
2.
Loosen locknuts and adjust rod as necessary.
contact the footboard when shifting. A minimum clear-
ance of 3/8 inch (9.5 mm) between shifter lever and foot-
3.
Install flat washer, lockwasher and locknut to fasten front
board must be maintained to accommodate engine
end of shifter rod to shifter lever.
movement when running.
4.
Tighten locknuts to 80-120 in-lbs (9.0-13.6 Nm).
1. Remove locknut, lockwasher and flat washer to free front
end of shifter rod from shifter lever. See Figure 7-2.
2005 Touring: Transmission
7-5
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