Harley Davidson 2005 touring models. Service repair manual — page 71
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FLYWHEEL/CONNECTING ROD ASSEMBLY
3.10
GENERAL
SPROCKET SHAFT BEARING
INNER RACE REPLACEMENT
For removal, inspection, and installation, see FLYWHEEL/
CONNECTING ROD ASSEMBLY under SUBASSEMBLY
SERVICE AND REPAIR in the Touring Models Service Man-
PART NO.
SPECIALTY TOOL
ual.
For service wear limits, refer to Table 3-21. and Table 3-22.
HD-44358
Flywheel support fixture
NOTE
HD-95637-46A
Wedge attachment
If the flywheel or connecting rods need to be replaced, then
they must be replaced together as one assembly.
Mainshaft bearing inner race
HD-34902B
puller/installer
HD-25070
Robinair heat gun
9978
1.
If reusing flywheel, remove bearing inner race and thrust
washer as follows:
a. Obtain FLYWHEEL SUPPORT FIXTURE
(HD-
44358). See Figure 3-36. Install brass jaws or shop
towels around teeth of vise to prevent damage to
tool. Clamp tool in vise with the round hole topside.
b. Insert crankshaft end through hole resting flywheel
assembly on fixture. Slide knurled locating pin down
slot in tool to engage crank pin hole. Hand tighten
locating pin.
c. Slide hold-down clamp down slot to engage inboard
side of right flywheel half, and then hand tighten
knurled nut at bottom to secure. Repeat step to
secure hold-down clamp on opposite side of fly-
wheel.
f1869x3x
1
2
Figure 3-35. FLHTCSE2
Flywheel/Connecting Rod Assembly
1.
Hold-down clamp
2.
Locating pin
Figure 3-36. Flywheel Support Fixture
(Part No. HD-44358)
2005 FLHTCSE2: Engine
3-27
HOME
NOTE
l.
After bottoming thrust washer on shaft, reposition
WEDGE ATTACHMENT
(HD-95637-46A) on
For proper clamping force, hold-down clamp must not be
inboard side of bearing inner race. Turn hex nuts an
tilted. Rotate hex on outboard stud until clamp is level.
equal number of turns to draw halves of wedge
d. Position WEDGE ATTACHMENT (HD-95637-46A)
together.
on inboard side of thrust washer and turn hex nuts
an equal number of turns to draw halves of wedge
CAUTION
together.
Install wedge attachment only so far as necessary to
CAUTION
ensure positive contact with bearing inner race. Install-
ing tool with more contact than absolutely necessary
Install wedge attachment only so far as necessary to
will result in damage to flywheel.
ensure positive contact with thrust washer. Installing
m.
Verify that the tool assembly is square, so that the
tool with more contact than absolutely necessary will
bearing inner race is not cocked during removal.
result in damage to flywheel.
See Figure 3-37.
e. Obtain two 3/8-16 inch bolts 6-1/2 inches long (with
n.
Using the ROBINAIR HEAT GUN (HD-25070), uni-
flat washers). Install flat washers on bolts. Obtain
formly heat the bearing inner race for about 30 sec-
bridge, forcing screw and hardened plug from
onds using a circular motion.
MAINSHAFT BEARING INNER RACE PULLER/
INSTALLER (HD-34902B).
f.
Slide one bolt into channel on each side of bridge
f2154x3
so that flat washer is between bridge and bolt head.
Thread bolts into wedge attachment an equal num-
1
ber of turns.
2
g. Sparingly apply graphite lubricant to threads of forc-
ing screw to prolong service life and ensure smooth
3
operation. Start forcing screw into center hole of
bridge.
CAUTION
7
4
Failure to use hardened plug may result in damage to
forcing screw and/or sprocket shaft.
h. Place cupped side of hardened plug against end of
sprocket shaft. Thread forcing screw into bridge until
6
5
the steel ball at the end of the screw makes firm
contact with hardened plug.
i.
Using the ROBINAIR HEAT GUN (HD-25070), uni-
formly heat the bearing inner race for about 30 sec-
onds using a circular motion.
NOTE
To facilitate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
1WARNING
Never use both heat and penetrating oil. Use only one or
the other. Excessive heat can cause the penetrating oil
to ignite resulting in flames or fire. Inadequate safety
1.
Forcing screw
precautions can result in death or serious injury.
2.
3/8-16 Inch bolt with flat washer
j.
Turn forcing screw until thrust washer and bearing
3.
Bridge
inner race move approximately 1/8 inch (3.2 mm).
4.
Hardened plug
k. Turn hex nuts an equal number of turns to separate
5.
Wedge attachment
halves of WEDGE ATTACHMENT.
6.
Bearing inner race
7.
Sprocket shaft
Figure 3-37. Remove Inner Race From Sprocket Shaft
3-28
2005 FLHTCSE2: Engine
HOME
NOTE
h97225-55B
To facilitate removal without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
o. Turn forcing screw until bearing inner race is pulled
free of sprocket shaft.
p. Remove thrust washer from sprocket shaft.
q. Discard thrust washer and bearing inner race.
2.
Place new thrust washer over sprocket shaft with the ink
stamp facing outside
(and the chamfer on the ID
inboard).
3.
Place new bearing inner race on bench top. Using the
ROBINAIR HEAT GUN (HD-25070), uniformly heat
Figure 3-38. Sprocket Shaft Timken Bearing
bearing inner race for about 60 seconds using a circular
Cone Installer (Part No. HD-97225-55B)
motion.
4.
Wearing suitable gloves to protect hands from burns,
f2152x3
place heated bearing inner race over sprocket shaft.
1
2
NOTE
To facilitate installation without heat, apply a light penetrating
oil to shaft and leading edge of bearing inner race.
1WARNING
4
3
Never use both heat and penetrating oil. Use only one or
the other. Excessive heat can cause the penetrating oil
5
6
to ignite resulting in flames or fire. Inadequate safety
7
precautions can result in death or serious injury.
5.
See Figure
3-38. Obtain the SPROCKET SHAFT
TIMKEN BEARING CONE INSTALLER (HD-97225-
55B). Assemble tool as described below.
a. See Figure 3-39. Thread pilot shaft onto sprocket
shaft until contact is made with shoulder.
b. Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and ensure smooth
operation.
c. Slide sleeve over pilot until it contacts bearing inner
f2153x3
race.
d. Slide Nice bearing and large flat washer over pilot
until contact is made with sleeve.
e. Thread handle onto pilot shaft. See upper frame of
Figure 3-39.
6.
Rotate handle of tool in a clockwise direction until bear-
ing inner race bottoms against thrust washer. See lower
frame of Figure 3-39.
7.
Remove handle, flat washer, Nice bearing, sleeve and
pilot from sprocket shaft.
1.
Pilot shaft
2.
Handle
3.
Flat washer
4.
Nice bearing
5.
Sleeve
6.
Inner race
7.
Thrust washer
Figure 3-39. Press Inner Race Onto Sprocket Shaft
2005 FLHTCSE2: Engine
3-29
HOME
OIL VENT LINE
3.11
REPLACEMENT
9968
5
PART NO.
SPECIALTY TOOL
2
3
4
1
HD-41137
Hose clamp pliers
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
1.
See Figure 3-40. Back the chrome nut off of the crank-
case oil fitting.
2.
Using side cutters, cut the clamps on the short length of
hose at the oil spout end of the vent line.
3.
Remove the oil vent line.
1.
Oil spout fitting
4.
If necessary, remove both fittings and clean sealant from
2.
Hose
threads in crankcase and oil fill.
3.
Oil vent line parallel to transmission cover
4.
S-bend
NOTE
5.
Crankcase fitting nut
The spout fitting is a nipple styled fitting.
5.
If removed, identify the crankcase end fitting and using
Figure 3-40. Oil Vent Line (clamps removed)
pipe sealant or TEFLON® tape, prepare the tapered
threaded end of fitting. Thread fitting into crankcase and
tighten to 130-150 in-lbs (14.7-16.9 Nm).
6.
If removed, identify oil spout fitting and using pipe seal-
ant or TEFLON® tape, prepare the tapered threaded end
of fitting. Thread fitting into oil spout and tighten to 130-
150 in-lbs (14.7-16.9 Nm).
7.
Slide crankcase fitting nut and rubber ferrule on crank-
case end of vent line.
8.
Push new hose with new clamps on the oil spout end of
chrome vent line.
9.
Orient s-bend in vent line toward crankcase and slide
chrome vent line into case fitting.
10. Push hose onto oil spout fitting.
11. Position line parallel with transmission cover and with
clearance to other components.
12. Push rubber ferrule into crankcase fitting. Thread
chrome nut over ferrule and hand tighten.
13. Tighten chrome nut to 60-80 in-lbs (6.8-9.0 Nm).
14. Using HOSE CLAMP PLIERS (HD-41137), crimp the
clamps on the hose.
15. Operate motorcycle and inspect for leaks.
3-30
2005 FLHTCSE2: Engine
HOME
OIL COOLER OPERATION
3.12
When the engine oil exceeds 210˚ F (99˚ C), the thermostat
GENERAL
is in its fully open position. See Fully Open Thermostat under
under 3.12 OIL COOLER OPERATION.
For engine oil flow through the engine, See ENGINE OIL
FLOW under GENERAL INFORMATION in Touring Models
In this position, all the oil flows through the oil cooler and
Service Manual.
back through the oil filter mount before returning to the crank-
case.
See Figure 3-41. The FLHTCSE2 is equipped with a factory
installed oil cooler controlled by a thermostat in the oil filter
NOTE
mount.
Regardless of whether the thermostat is closed, partially
open or fully open, oil is always pressurized in the transfer
Engine oil flows from the crankcase through the oil filter
passage, the oil cooler supply hose, the oil cooler and the oil
mount to the oil cooler through a supply hose. The oil circu-
return hose.
lates through the finned tubes of the cooler to dissipate heat
and returns to the oil filter mount through a return hose.
The oil cooler should always be checked for dirt and debris to
maintain cooler efficiency at every service interval.
Under pressure from the crankcase, engine oil enters the
lower port in the oil filter mount. A passage way directs oil to
flow to the oil filter. The oil circulates through the oil filter ele-
ment and out the oil filter threaded fitting.
8871
1
From the oil filter, the filtered oil flows in two directions:
2
3
● From the oil filter adapter into the thermostat chamber.
● Through a side passage and out the supply oil fitting to
the oil cooler.
4
See Figure 3-43.The thermostat chamber is located in line
with the return port to the engine crankcase. The thermostat
assembly consists of a temperature sensitive plunger com-
5
pressed between a spring-loaded piston, spring and an open
cage spreader.
6
While the engine oil temperature is below 180˚ F (82˚ C), the
thermostat is in its closed position. See Closed Thermostat
under 3.12 OIL COOLER OPERATION.
The filtered oil is circulated through the transfer passage
7
where it returns to the crankcase. At the same time, oil is
supplied under pressure to the oil cooler even though the oil
cooler return port is blocked.
8
While the engine operates at average temperatures, approxi-
mately 195˚ F (91˚ C), the thermostat partially opens allowing
cooler oil from the cooler to mix with warmer oil from the oil
1.
Oil filter mount
transfer passage as the oil returns to the crankcase. See Par-
2.
Transfer passage cover
tially Open Thermostat under 3.12 OIL COOLER OPERA-
3.
Thermostat plug
TION.
4.
Oil return fitting
5.
Oil supply fitting
6.
Supply hose
7.
Return hose
8.
Oil cooler
Figure 3-41. Oil Cooler and Bracket
(chrome cover removed for photo clarity)
2005 FLHTCSE2: Engine
3-31
HOME
9980
8872
1
3
1
2
2
4
4
6
3
5
1.
Transfer passage cover
2.
Thermostat plug
8875
3.
Return hose fitting
4.
Supply hose fitting
Figure 3-42. Oil Filter Mount on Engine
9982a
7
3
6
4
5
1
2
8
1.
Open cage spreader
2.
Thermostat plunger
3.
Piston
4.
Spring
5.
O-ring
6.
Thermostat plug
Figure 3-43. Thermostat Assembly
9931
1
1.
Oil filter adapter
2
2.
Passage to oil filter element
3.
Return to crankcase
4.
Supply from crankcase
5.
Return hose fitting
6.
Supply hose fitting
7.
Open passage from oil filter
8.
Open passage to oil cooler supply
Figure 3-45. Oil Filter Mount
1. Return port to crankcase (thermostat removed)
2. Supply port from crankcase
Figure 3-44. Oil Filter Mount Ports to Crankcase
3-32
2005 FLHTCSE2: Engine
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Closed Thermostat
8876
See Figure 3-46. While the engine oil is cool, the thermostat
1
2
is in its closed position. The spring holds the piston over the
return passage from the oil cooler. Even though oil pressure
is supplied to the oil cooler, oil is blocked from returning from
the oil cooler.
See Figure 3-47. When closed, the piston opens a port in the
transfer passage along the side of the thermostat chamber.
The filtered oil is circulated around the piston through the
transfer passage and into a port in the thermostat chamber
where it flows through the open cage spreader and returns to
the crankcase.
Partially Open Thermostat
As the engine oil exceeds 180˚ F (82˚ C), the thermostat
plunger begins to expand and compresses the spring push-
ing against the piston. The piston partially opens the return
passage from the oil cooler and partially closes the port from
the chamber to the transfer passage.
While the engine operates at an average temperature, 195˚ F
(91˚ C), the thermostat remains partially open allowing cooler
oil from the cooler to mix with warmer oil from the oil filter.
1. Return passage from oil cooler
2. Open passage from oil filter
Fully Open Thermostat
Figure 3-46. Thermostat Chamber
See Figure 3-48. The thermostat fully opens when the engine
oil temperature exceeds 210˚ F (99˚ C). The piston fully
8874
1
2
3
closes the port to the transfer passage and opens the return
passage from the oil cooler.
In this position, all the oil flows from the oil filter through the
oil cooler and back through the return passage before return-
ing to the crankcase. The oil from the oil cooler return will
back up under pressure in the transfer passage even though
the port from the oil filter is closed.
1.
Port open from oil filter
2.
Oil under pressure
3.
Port open to crankcase return
Figure 3-47. Closed Thermostat
8873
1
2
3
1.
Port open to oil cooler return
2.
Oil under pressure
3.
Port closed from oil filter
Figure 3-48. Fully Open Thermostat
2005 FLHTCSE2: Engine
3-33
HOME
OIL COOLER
3.13
REMOVAL
INSTALLATION
1.
Cover the front fender to protect finish.
PART NO.
SPECIALTY TOOL
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
HD-41137
Hose clamp pliers
2.
Place a container under the motorcycle to catch excess
oil.
1.
If replacing the hoses, install new hoses with clamps at
3.
Remove the fasteners holding the oil cooler and cover to
the oil filter mount. Using HOSE CLAMP PLIERS (HD-
mounting bracket.
41137), clamp the supply and return hoses at the oil fil-
ter mount.
4.
Pull the cooler and cover forward and, using side cutters,
cut the clamps on the supply and return hoses.
2.
Apply LOCTITE Thread Sealant to threads of oil pres-
sure switch and install oil pressure switch. Tighten to 96-
5.
Remove the oil cooler with cover.
144 in-lbs (10.8-16.3 Nm).
NOTE
3.
Connect oil pressure switch wire lead.
The oil cooler guard is held in place with adhesive tape.
4.
Attach hoses to oil cooler. Using HOSE CLAMP PLIERS
6.
If replacing the oil hoses, remove oil pressure switch to
(HD-41137), clamp the supply and return hoses at the
gain access to clamps. Cut clamps at oil filter mount.
oil cooler.
Remove oil hoses.
5.
Install oil cooler and cover to mounting bracket. Tighten
7.
The oil cooler should be checked for dirt and debris.
fasteners to 80-110 in-lbs (9.1-12.4 Nm).
6.
Operate motorcycle and inspect for leaks.
8871
1
2
3
4
1.
Return hose clamp
2.
Supply hose clamp
3.
Oil cooler and guard
4.
Bracket
Figure 3-49. Oil Cooler and Mount
(chrome cover removed for photo clarity)
3-34
2005 FLHTCSE2: Engine
HOME
OIL FILTER MOUNT
3.14
REMOVAL
9980
PART NO.
SPECIALTY TOOL
HD-42311 or HD-44067
Oil filter wrench
1.
Place a container under motorcycle to catch excess oil.
2.
Bend a cardboard funnel and fit to motorcycle to route
fluid away from regulator and oil cooler to container.
3.
Using OIL FILTER WRENCH (HD-42311 or HD-44067),
remove oil filter. Discard oil filter
IMPORTANT NOTE
Dispose of oil in accordance with local regulations.
4.
If necessary, remove the threaded oil filter adapter and
oil pressure switch.
5.
Using side cutters, cut the clamps and remove oil cooler
hoses.
6.
If necessary, loosen but do not remove thermostat plug.
Figure 3-50. Oil Filter Mount (engine removed from frame)
7.
Bend tabs of the lockplate away from bolt heads.
8.
Remove oil filter mount lockplate fasteners and flat
washers. Discard lockplate.
9931
9.
Remove middle bolt with flat washer and remove oil filter
mount.
DISASSEMBLY
1.
If necessary, remove the thermostat. See 3.15 THER-
MOSTAT.
2.
See Figure 3-51. Remove the o-rings in the oil filter
mount.
3.
Remove the transfer passage cover.
4.
Remove the transfer passage cover gasket.
5.
Remove the two oil cooler line fittings.
6.
Clean the oil passages in a cleaning solution or solvent.
7.
Remove thread locking adhesive from the threads of the
oil filter adapter.
Figure 3-51. Oil Filter Mount O-rings
(thermostat removed)
8.
Inspect the oil passages and the oil filter mount.
2005 FLHTCSE2: Engine
3-35
HOME
ASSEMBLY
CAUTION
1.
See Figure 3-52. Install a new gasket on the transfer
To avoid cross threading tapped holes, exercise care
passage cover.
when starting hex head bolts in crankcase.
2.
Install the transfer passage cover. Tighten to 90-120 in-
7.
Align holes in filter mount flange with holes in crankcase
lbs (10.2-13.6 Nm).
and tighten bolts until snug.
3.
Using pipe sealant or TEFLON tape, prepare the
8.
Install flat washer on remaining fastener, apply LOCTITE
tapered threaded end of oil supply and return fittings and
to threads and install in middle hole of mount flange.
install fittings.
9.
Starting at the top, alternately tighten the fasteners to
4.
If removed, replace the thermostat components:
130-150 in-lbs (14.7-16.9) Nm.
a. Replace the spreader.
10. Bend the ends of the lockplate to capture the top and
b. Replace the thermostat plunger and piston.
bottom fasteners.
c. Replace the spring.
11. If disassembled, tighten the Thermostat plug to 15-20 ft-
d. Install a new o-ring and loosely install thermostat
lbs (20.4-27.1 Nm).
plug.
12. Apply LOCTITE THREADLOCKER 243 (blue) to tapered
threads of oil filter adapter. Install oil filter adapter and
tighten to 12-16 ft-lbs (16.3-21.7 Nm).
INSTALLATION
13. Install a new oil filter. See SCHEDULED MAINTE-
NANCE in Touring Models Service Manual.
PART NO.
SPECIALTY TOOL
NOTE
If removed, install oil pressure switch using LOCTITE Thread
HD-41137
Hose clamp pliers
Sealant and tighten to 96-144 in-lbs (10.9-16.3 Nm).
1.
Install the oil cooler oil hoses to the filter mount with new
clamps.
9996
2.
Using HOSE CLAMP PLIERS (HD-41137), crimp the
clamps.
3.
Place flat washers in recessed bolt holes at top and bot-
tom of filter mount flange.
4.
Align holes in lockplate with holes in flat washers.
5.
Slide two fasteners through lockplate, flat washers and
filter mount flange. Apply LOCTITE
243 (blue)
(HD-
99642-97) to threads of installed bolts.
6.
See Figure 3-51. Install new o-rings into grooves in oil
filter mount.
Figure 3-52. Transfer Passage Cover and Gasket
3-36
2005 FLHTCSE2: Engine
HOME
THERMOSTAT
3.15
TEST PROCEDURE
REMOVAL
1.
Using an infrared thermometer, measure the tempera-
1.
Allow the motorcycle to cool.
ture at the oil pan and at the oil cooler while operating
2.
Place a catch pan under motorcycle.
motorcycle.
3.
Bend a cardboard funnel and fit to motorcycle to route
2.
Compare temperatures.
fluid away from regulator and oil cooler to container.
a. If the temperature of the oil cooler follows the tem-
IMPORTANT NOTE
perature of the oil pan at temperatures below 180˚ F
Dispose of oil in accordance with local regulations.
(82˚ C), then the thermostat may be stuck open.
Allow the engine to cool, remove the thermostat.
4.
See Figure 3-53. With a ball Allen wrench, loosen and
and proceed.
remove the thermostat plug.
b. If the temperature of the oil cooler is less than that
5.
Remove the spring.
of the oil pan below 180˚ F (82˚ C) but, above 180˚
6.
Remove the thermostat plunger and piston with a pair of
F (82˚ C), follows the temperature of the oil pan, the
needle nosed pliers.
thermostat is operating correctly.
7.
Remove the open cage spreader with a pick.
c. If the oil pan exceeds 210˚ F (99˚ C) and the oil
cooler is cooler, then the thermostat may be stuck
closed. Allow the engine to cool, remove the ther-
INSTALLATION
mostat and proceed.
1.
See Figure 3-53. Insert the open cage spreader part
3.
Verify that thermostat plunger is fully retracted.
way into thermostat chamber.
4.
Place thermostat plunger in a container of water with a
2.
Install the thermostat plunger and piston together.
thermometer.
3.
Locate the plunger in the spreader and push in to bottom
5.
Refer to Table 3-29. Heat water to START TO OPEN
of chamber.
temperature. Verify that the plunger extends.
4.
Install the spring.
6.
Heat water pass START TO OPEN temperature to FULL
OPEN temperature and verify that plunger is fully
5.
Fit a new o-ring and install thermostat plug. Tighten to
extended.
15-20 ft-lbs (20.4-27.1 Nm).
7.
If plunger does not extend per specifications, replace
thermostat assembly.
9982
Table 3-29. Thermostat Operating Range
6
3
4
5
1
ITEM
FAHRENHEIT
CELSIUS
2
START TO OPEN (closed)
180˚
82˚
AVERAGE (partially open)
195˚
91˚
FULL OPEN (fully open)
210˚
99˚
1.
Open cage spreader
2.
Thermostat plunger
3.
Piston
4.
Spring
5.
O-ring
6.
Thermostat plug
Figure 3-53. Thermostat Components
2005 FLHTCSE2: Engine
3-37
FUEL SYSTEM
4
Table Of Contents
NOTE
All fuel system service procedures in the current Touring Models Service Manual apply to
the FLHTCSE2 model motorcycle.
ELECTRIC STARTER
5
Table Of Contents
SUBJECT
PAGE NO.
5.1 Specifications
5-1
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
HOME
SPECIFICATIONS
5.1
Table 5-1. Starter
ITEM
SPECIFICATION
Free (no load) speed
3000 RPM (min.) @ 11.5 V
Free (no load) current
90 amp (max.) @ 11.5V
Stall torque
8.7 ft-lbs (11.8 Nm) min. @ 2.4 V
(500 Amps max.)
2005 FLHTCSE2: Electric Starter
5-1
Table Of Contents
SUBJECT
PAGE NO.
6.1 Specifications
6-1
6.2 Torque Values (table)
6-2
6.3 Clutch Release Bearing and Push Rod
6-3
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
DRIVE
6
HOME
SPECIFICATIONS
6.1
Table 6-1. Gear Ratios
Table 6-4. Drive Belt Deflection
GEAR
RATIO
DEFLECTION
INCHES
MM
1
10.11
On Jiffy Stand
Without Rider or
2
6.958
1/4-5/16
6.4-7.9
Luggage with 10-
at 10 lbs force
at 4.5 kg force
3
4.953
psi (69 kPa) in
Rear Shocks
4
3.862
5
3.15
Motorcycle
3/16-1/4
4.8-6.4
Upright With rear
at 10 lbs force
at 4.5 kg force
Wheel in Air
Table 6-2. Primary Chain Free Play
FREE PLAY
INCHES
MM
Table 6-5. Sprockets
5/8-7/8
15.9-22.2
COLD Engine
SPROCKET
NUMBER OF TEETH
HOT Engine
3/8-5/8
9.5-15.9
Engine
25
Clutch
36
Transmission
32
Rear wheel
70
Table 6-3. Primary Chaincase Lubricant
ITEM
VALUE
Amount
32 oz (946 ml)
Part No.
99824-03/00QT
2005 FLHTCSE2: Drive
6-1
HOME
TORQUE VALUES
6.2
ITEM
TORQUE
NOTES
Clutch inspection cover
84-108 in-lbs
9.5-12.2 Nm
page 6-4
6-2
2005 FLHTCSE2: Drive
HOME
CLUTCH RELEASE BEARING AND PUSH ROD
6.3
GENERAL
10950
See Figure 6-1. The following procedure covers removal of
clutch release bearing and push rod assembly.
REMOVAL
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a)
1.
Remove Maxi-Fuse.
2.
Remove clutch inspection cover.
3.
See Figure 6-2. Remove bearing plate retaining ring (1).
Figure 6-1. Clutch Release Bearing
4.
Pull out release bearing plate (3) with release bearing
(4) and push rod (5).
5.
Remove push rod retainer (2).
cse0011x7x
6.
Press release bearing out of bearing plate.
INSTALLATION
2
1.
See Figure 6-2. Pressing on the outer race, press a new
5
release bearing (4) into bearing plate (3).
2.
Assemble push rod (5) to bearing.
3.
Snap in push rod retainer (2).
4
4.
Slide push rod and clutch release bearing assembly
through clutch pack to secondary clutch actuator.
3
1
5.
Snap in bearing plate retaining ring (1).
1.
Bearing plate retaining ring
2.
Push rod retainer
3.
Release bearing plate
4.
Release bearing
5.
Push rod
Figure 6-2. Push Rod And Release Bearing
2005 FLHTCSE2: Drive
6-3
HOME
NOTE
f1209a6x
Before installing clutch inspection cover check push rod and
release plate movement as follows.
Measuring Release Plate Movement
1.
Attach the standoff of a dial indicator to one of the 1/4-20
clutch-inspection (derby) cover mounting holes or use a
magnetic base and dial indicator mounted suitably. Posi-
1
tion the indicator anvil (rod) to the end of the push rod.
3
4
1WARNING
Insufficient clutch-release plate movement can lead to
2
5
difficulty or inability to shift, causing loss of control,
which could result in death or serious injury.
2.
Actuate the clutch lever to measure the axial movement
of the push rod and the clutch-release plate assembly.
The axial movement must be at least 0.065 in. (1.65
mm).
NOTE
Figure 6-3. Clutch Inspection Cover Torque Sequence
Proper bleeding of the system will typically yield plate move-
ment of greater than 0.065 in. (1.65 mm). If clutch release
plate movement is less than 0.065 in. (1.65 mm), the system
must be re-bled and plate movement checked again.
Installing Clutch Inspection Cover
1.
Thoroughly clean all gasket material from clutch inspec-
tion cover and mating surface on primary cover.
2.
See Figure 6-3. Install clutch inspection cover with new
gasket. Make sure the correct side of the gasket faces
the clutch inspection cover. In sequence, tighten fasten-
ers to 84-108 in-lbs (9.5-12.2 Nm).
3.
Install Maxi-Fuse.
6-4
2005 FLHTCSE2: Drive
Table Of Contents
SUBJECT
PAGE NO.
7.1 Specifications
7-1
7.2 Service Wear Limits
7-2
7.3 Torque Values (table)
7-3
7.4 Clutch Release Cover
7-4
7.5 Secondary Clutch Actuator
7-6
NOTE
This section provides information unique to FLHTCSE2 model motorcycles. Any informa-
tion not presented in this supplement can be found in the Touring Models Service Manual.
TRANSMISSION
7
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