Harley Davidson 2005 touring models. Service repair manual — page 19
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STARTER JACKSHAFT
5.6
REMOVAL/DISASSEMBLY
1. Remove seat. See Section 2.24 SEAT, REMOVAL.
7945
1WARNING
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.
2. Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3. See Figure 5-21. Remove the primary chaincase cover.
Remove the clutch assembly, primary chain and com-
pensating sprocket components as a single assembly.
See Section 6.5 PRIMARY CHAINCASE, REMOVAL,
steps 3-15.
Starter
Jackshaft
NOTE
Assembly
If only the jackshaft bolt, thrust washer, lockplate, pinion gear
and/or spring require servicing, then the primary chain and
Figure 5-21. Primary Chaincase
clutch assembly may be left in place.
Retaining
Ring
f1211c5x
Keyway
Output
Coupling
Shaft
Coupling
Counterbore
Spring
Jackshaft
Slot
Key
Retaining
Ring
Primary Chaincase
Jackshaft
Bushing
Pinion
Bolt
Gear
Primary
Cover Bushing
Tab
Thrust
Washer
Lockplate
Figure 5-22. Starter Jackshaft Assembly
5-14
2005 Touring: Starter
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4. Bend tab on lockplate away from head of jackshaft bolt.
3.
Install oil filler plug/dipstick at top of transmission case.
See Figure 5-22.
4.
Install slot of exhaust support bracket onto stud of
5. Holding pinion gear to prevent rotation, remove the jack-
bracket tab aligning other holes with those in starter
shaft bolt with lockplate and thrust washer.
flange. Start Keps nut on stud.
6. Carefully pull jackshaft assembly from the primary chain-
5.
Engaging hole in exhaust support bracket, install starter
case bore.
front mounting screw with lockwasher. Install rear
mounting screw with lockwasher (and battery negative
7. Remove the pinion gear from the jackshaft.
cable ring terminal) in the same manner.
8. Remove the coupling from the jackshaft. Remove the
6.
Alternately tighten starter front and rear mounting
spring from the coupling.
screws to 14-18 ft-lbs (19-24 Nm). Tighten Keps nut on
stud of bracket tab.
CAUTION
7.
Install battery positive and main power cable ring termi-
Do not force the output shaft coupling through the oil
nals onto starter post. Install flange nut and tighten to
seal in the primary chaincase or the resulting damage
70-90 in-lbs (7.9-10.2 Nm). Pull down rubber boot over
will require seal replacement.
terminal connections on starter post.
8.
Snap solenoid connector to terminal at top of starter
9. From right side of motorcycle, remove starter front
housing.
mounting screw with lockwasher. Remove rear mounting
screw with lockwasher (and battery negative cable ring
NOTE
terminal). Remove Keps nut from stud of bracket tab and
If removed, install allen screw to fasten decorative chrome
remove exhaust support bracket.
cover to starter.
10. Pull back rubber boot and remove flange nut from starter
post. Remove main power and battery positive cable
9.
Inspect the retaining ring within the coupling for damage
ring terminals from starter post.
or distortion. Replace as necessary.
11. Depress external latch and pull solenoid connector from
10.
Insert narrow end of jackshaft into shallow side of cou-
top of starter housing.
pling until gear face contacts installed retaining ring.
(Look at position of retaining ring within coupling to
12. Locate oil filler plug/dipstick at top of transmission case.
determine shallow side.)
To remove the oil filler plug, pull steadily while moving
plug back and forth.
11.
Slide spring over narrow end of jackshaft until it contacts
retaining ring.
13. Remove the starter from the right side of the motorcycle,
carefully sliding it through the space between the
12.
Slide pinion gear over narrow end of jackshaft until it
exhaust pipe and side cover.
contacts spring.
NOTE
13.
Slide lockplate and new thrust washer onto jackshaft
bolt, if removed. Insert bolt into jackshaft bore.
If necessary, remove allen screw and decorative chrome
cover to facilitate starter removal.
14.
Gently insert jackshaft assembly into primary chaincase
so that splined end of shaft engages coupling on starter
14. Remove the coupling from the starter motor output shaft.
output shaft.
15.
Insert key on lockplate through slot in thrust washer and
into keyway on jackshaft. Thread the jackshaft bolt into
ASSEMBLY/INSTALLATION
the starter shaft making sure that the lockplate key
remains in the keyway.
NOTE
16.
Holding pinion gear to prevent rotation, tighten jackshaft
bolt to 60-80 in-lbs (6.8-9.0 Nm). Bend tab on lockplate
To replace the jackshaft bushings and/or seals in the primary
against flat of bolt head to secure.
chaincase or primary chaincase cover, see Section 6.5 PRI-
MARY CHAINCASE, DISASSEMBLY.
17.
Install the clutch, primary chain, and compensating
sprocket components. Install the primary chaincase
1. Inspect the retaining ring within the output shaft coupling
cover. See Section
6.5 PRIMARY CHAINCASE,
for damage or distortion. Replace as necessary. With the
INSTALLATION, steps 9-31.
counterbore on the outboard side, install the coupling on
the starter motor output shaft, if removed.
18.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
2. From right side of motorcycle, tilt starter and work into its
bolt to 60-96 in-lbs (6.8-10.9 Nm).
installed position. Starter output shaft coupling must
remain on shaft and mate to starter jackshaft.
19.
Install seat. See Section 2.24 SEAT, INSTALLATION.
2005 Touring: Starter
5-15
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NOTES
5-16
2005 Touring: Starter
Table Of Contents
SUBJECT
PAGE NO.
6.1 Specifications
6-1
6.2 Primary Chain And Sprockets
6-3
6.3 Clutch
6-6
6.4 Secondary Drive Belt And Sprockets
6-11
6.5 Primary Chaincase
6-17
DRIVE
6
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SPECIFICATIONS
6.1
OVERALL GEAR RATIOS
SPROCKETS
Overall gear ratios indicate the number of engine revolutions
required to drive the rear wheel one revolution.
Number of Teeth
Sprocket
All Models
Gear
All Models
Engine
25
1
10.11
Clutch
36
2
6.96
Transmission
32
3
4.95
Rear wheel
70
4
3.86
5
3.15
CLUTCH
CHAINS AND BELTS
Clutch
Description
Type
Wet-multiple disc
Primary Chain Adjustments
1/16-1/8 in.
Clutch lever free play
1.6-3.2 mm
Free Play
Inches
Millimeters
loosen 1/2-1 turn after
Clutch screw adjustment
lightly seating
COLD Engine
5/8-7/8 inch
15.9-22.2 mm
HOT Engine
3/8-5/8 inch
9.5-15.9 mm
TORQUE VALUES
Primary Chaincase Lubricant
Item
ft/in-lbs
Nm
Primary chain tensioner
Ounces
Milliliters
21-29 ft-lbs
29-39 Nm
shoe nut
Amount
32
946
Tensioner shoe adjuster
12-14 ft-lbs
16-19 Nm
plate screws
Quart
Gallon
Primary chain inspection
84-108 in-lbs
10-12 Nm
Part Number
cover screws
99887-84
99886-84
Clutch adjuster screw
72-120 in-lbs
8-14 Nm
locknut
Rear Belt Adjustment
Clutch inspection cover
84-108 in-lbs
10-12 Nm
screws
Deflection
Inches
Millimeters
Clutch diaphragm spring
90-110 in-lbs
10-12 Nm
retainer to clutch hub bolts
On Jiffy Stand Without
Rear axle cone nut
95-105 ft-lbs
129-142 Nm
Rider or Luggage
1/4 - 5/16
6.4
- 7.9
Rear swingarm pivot
10 psi (69 kPa)
at 10 lbs force
at 4.5 kg force
40-45 ft-lbs
54-61 Nm
shaft locknut
in Rear Shocks
Rear swingarm bracket
Motorcycle Upright
34-42 ft-lbs
46-57 Nm
3/16 - 1/4
4.8
- 6.4
bolts
With Rear Wheel
at 10 lbs force
at 4.5 kg force
Continued ...
in the Air
2005 Touring: Drive
6-1
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TORQUE VALUES (CONT.’D)
Item
ft/in-lbs
Nm
Exhaust pipe TORCA
45-60 ft-lbs
61-81 Nm
clamps
Heat shield worm drive
20-40 in-lbs
2.3-4.5 Nm
clamp screws
Transmission mainshaft
60 ft-lbs, then
81 Nm, then
sprocket nut
35° to 45°
35° to 45°
Mainshaft sprocket nut
lockplate socket head
84-108 in-lbs
9-12 Nm
screws
Rear wheel sprocket bolts
55-65 ft-lbs
75-88 Nm
Primary chaincase to
crankcase and transmis-
18-21 ft-lbs
24-28 Nm
sion
Starter front and rear
14-18 ft-lbs
19-24 Nm
mounting screws
Starter jackshaft bolt
60-80 in-lbs
6.8-9.0 Nm
Engine compensating
150-165 ft-lbs
203-224 Nm
sprocket nut
Clutch hub mainshaft nut
70-80 ft-lbs
95-108 Nm
Primary chaincase cover
84-108 in-lbs
9-12 Nm
allen head socket screws
Primary chaincase drain
36-60 in-lbs
4.1-6.8 Nm
plug
Passenger footboard
15-18 ft-lbs
20-24 Nm
socket screws
Shifter lever
1/4”
90-110 in-lbs
10.2-12.4 Nm
socket screws
5/16”
18-22 ft-lbs
24-30 Nm
6-2
2005 Touring: Drive
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PRIMARY CHAIN AND SPROCKETS
6.2
PRIMARY CHAIN ADJUSTMENT
Table 6-1. Primary Chain Adjustment
See Section 1.7 PRIMARY CHAIN/LUBRICANT, PRIMARY
(Free Play)
Inches
Millimeters
CHAIN ADJUSTMENT.
COLD ENGINE
5/8-7/8 inch
15.9-22.2 mm
HOT ENGINE
3/8-5/8 inch
9.5-15.9 mm
ADJUSTER SHOE REPLACEMENT
10. If the chain is too tight or too loose, then adjust as fol-
If the nylon adjuster shoe is worn or damaged, replace as fol-
lows:
lows:
a. Loosen the top center nut a maximum of two turns
1. Remove the primary chaincase cover. See Section 6.5
and raise or lower the chain tensioner assembly as
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
necessary to obtain the specified free play. See Fig-
2.
Loosen top center nut from captured bolt of chain ten-
ure 6-1.
sioner assembly. See Figure 6-1.
NOTE
3.
Lower the chain tensioner assembly until the adjuster
As chains stretch and wear, they run tighter at one spot than
shoe just contacts the inner primary housing.
another. Always adjust the free play at the tightest spot in the
chain. Replace the primary chain if it is worn to the point
where it cannot be properly adjusted.
1WARNING
Always wear proper eye protection when removing re-
CAUTION
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
Always keep the primary chain properly adjusted. Allow-
worn. Slippage may propel the ring with enough force to
ing the chain to run too tight or too loose will result in
cause eye injury.
excessive chain and sprocket wear.
4.
Remove retaining ring from nub and pull adjuster shoe
b. Tighten the top center nut of the chain tensioner
from chain tensioner. Discard adjuster shoe and retain-
assembly to 21-29 ft-lbs (29-39 Nm).
ing ring.
11. Install the primary chaincase cover. See Section 6.5
5. Slide new adjuster shoe onto chain tensioner. Be sure
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
that the narrow end of the shoe is at the front, the wider
end at the rear.
f1840x6x
1WARNING
Top Center Nut
Always wear proper eye protection when installing re-
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.
Primary
6.
Install new retaining ring onto nub of chain tensioner to
Chain
lock position of adjuster shoe. Verify that retaining ring is
fully seated in the groove.
7.
Raise the chain tensioner assembly and then snug the
top center nut.
8.
Check the primary chain tension. Push on the upper
strand to verify that it has free up and down movement
midway between the engine compensating sprocket
(front) and the clutch sprocket (rear).
Adjuster Shoe
Retaining
Narrow End Forward
9.
Measure the free play to be sure that it falls within the
Ring
range specified for a hot or cold engine:
Figure 6-1. Chain Tensioner Assembly
2005 Touring: Drive
6-3
HOME
f1096dxd
6
1
3
5
4
2
1.
Sprocket Nut
6. Alternator Rotor Spacer-
7.
Alternator Rotor
2.
Sprocket Cover
Low Output Rotor Only
8.
Sprocket Shaft Spacer
3.
Sliding Cam
0.020 inch (0.508 mm)
9.
Engine Sprocket Shaft
4.
Compensating Sprocket
5.
Shaft Extension
EXPLODED VIEW
4
3
2
NOTE
Alternator stator, oil seal and left
crankcase not shown.
1
5
9
8
6
CROSS SECTIONAL VIEW
7
Figure 6-2. Engine Compensating Sprocket Components
DISASSEMBLY
CLEANING AND INSPECTION
See Section 6.5 PRIMARY CHAINCASE, REMOVAL, steps
1.
Periodically inspect the primary chain for cracked, bro-
1-16.
ken or badly worn links. Replace as necessary.
6-4
2005 Touring: Drive
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2. Inspect compensating sprocket components for damage
or wear. Replace parts as necessary.
Measure at Compensating Sprocket
3. Inspect clutch sprocket for damage or wear. If broken or
A
damaged teeth are found, the clutch shell and sprocket
assembly must be replaced.
Sprocket Alignment (Figure 6-2, 6-3)
The engine compensating sprocket is aligned with the clutch
sprocket by a spacer installed between the alternator rotor
and shaft extension (low output rotor only). Reinstall the
same thickness spacer removed or determine the correct
Dial Vernier
spacer size as follows:
Caliper
1.
With the primary chaincase cover removed, verify that
the primary chain tension is properly adjusted. See
ADJUSTER SHOE REPLACEMENT in this section,
steps 8-10.
Straightedge
7949
2.
At both the engine compensating sprocket and clutch
sprocket sides, push the primary chain inward as far as it
will go.
3.
Place a straightedge vertically across the flanges (cover
Measure at Clutch Sprocket
B
gasket surface) near the engine compensating sprocket.
4.
Using a dial vernier caliper, measure the distance from
the straightedge to the chain link sideplate. Measure as
close to the engine compensating sprocket as possible
and record the measurement. See A of Figure 6-3.
5.
Repeat the measurement on the clutch sprocket side.
See B of Figure 6-3.
For proper primary chain alignment, the difference
between the two measurements must not exceed 0.030
inch (0.76 mm). If the measurement is not within specifi-
cation, install the appropriate variable thickness spacer
on the engine sprocket shaft between the alternator rotor
and shaft extension. See the table below for the various
spacer thicknesses.
7947
Figure 6-3. Check Sprocket Alignment
Table 6-2. Alternator Rotor Spacers
Inches
Millimeters
Part Number
ASSEMBLY
0.010
0.25
35850-84
0.020
0.51
35851-84
See Section 6.5 PRIMARY CHAINCASE, INSTALLATION,
steps 8-31.
0.030
0.76
35852-84
0.060
1.52
24032-70
0.090
2.29
24033-70
0.120
3.05
24034-70
0.150
3.81
24035-70
0.180
4.57
24036-70
0.210
5.33
24037-70
2005 Touring: Drive
6-5
HOME
CLUTCH
6.3
3.
Remove diaphragm spring retainer, diaphragm spring
ADJUSTMENT
and pressure plate from clutch hub.
4.
Remove friction plates, steel plates, damper spring and
See Section 1.8 CLUTCH ADJUSTMENT.
damper spring seat from clutch hub.
5.
See CLEANING AND INSPECTION in this section.
REMOVAL/INSTALLATION
ASSEMBLY
To remove the clutch without disassembly, see Section 6.5
CLUTCH PACK ONLY
PRIMARY CHAINCASE, REMOVAL, steps 1-16.
1.
Submerge and soak all friction and steel plates in PRI-
For installation instructions, see Section
6.5 PRIMARY
MARY CHAINCASE LUBRICANT for at least five min-
CHAINCASE, INSTALLATION, steps 8-31.
utes.
2.
Install the narrow friction plate on the clutch hub engag-
NOTE
ing tabs on plate with slots in clutch shell.
If only the clutch pack is to be disassembled, see PARTIAL
DISASSEMBLY below, a procedure that can be performed on
3.
Install damper spring seat on clutch hub so that it seats
the motorcycle without removing the clutch shell or hub.
inboard of narrow friction plate.
4.
Install damper spring on clutch hub with the concave
For complete disassembly of the clutch, which includes
side up (facing opposite damper spring seat). See Fig-
clutch pack disassembly and bearing replacement, see
ure 6-4.
COMPLETE DISASSEMBLY.
5.
Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
PARTIAL DISASSEMBLY
alternating between steel plates and friction plates.
6.
Install pressure plate on clutch hub aligning holes in
CLUTCH PACK ONLY
plate with threaded bosses on hub.
1.
Remove the primary chaincase cover. See Section 6.5
7.
Seat diaphragm spring in recess of pressure plate with
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
the concave side down.
2.
Remove six bolts to release diaphragm spring retainer
8.
Align holes in diaphragm spring retainer with threaded
from clutch hub. See Figure 6-5.
bosses on clutch hub. Tabs on spring retainer contact
flats on inboard side of bosses.
9.
Install six bolts to secure diaphragm spring retainer to
f1523x6x
clutch hub. Alternately tighten bolts to
90-110 in-lbs
Damper
Clutch
Spring
Hub
(10.2-12.4 Nm).
10.
Install the primary chaincase cover. See Section 6.5
Clutch
Shell
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
Steel Plate
CLEANING AND INSPECTION
1. Wash all parts in cleaning solvent, except for friction
plates and bearing, if removed. Blow dry with com-
pressed air.
2. Check friction plates as follows:
● Wipe all lubricant from the friction plates. Measure
Damper
Narrow
the thickness of each plate with a dial caliper or
Spring Seat
Friction Plate
micrometer. If the thickness of any plate is less than
0.143 inch (3.62 mm), discard the friction plates and
replace with an entirely new set.
● Look for worn or damaged fiber surface material
Figure 6-4. Clutch Pack Stack-Up (Cut-Away View)
(both sides).
6-6
2005 Touring: Drive
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f1514x6x
5
6
4
2
3
7
8
1
9
10
11
17
16
14
18
15
19
12
23
20
13
21
1. Retaining Ring
24
2. Clutch Shell
22
3. Bearing
10. Damper Spring
4. Retaining Ring
11. Damper Spring Seat
5. Clutch Hub
12. Pressure Plate
17. Retaining Ring
6. Mainshaft Nut
13. Diaphragm Spring
18. Locknut
7. Friction Plate (9)
14. Diaphragm Spring Retainer
19. Adjuster Screw
22. Thrust Washer (2)
8. Steel Plate (8)
15. Bolt (6)
20. Push Rod
23. Throw Out Bearing
9. Narrow Friction Plate
16. Release Plate
21. Oil Slinger
24. Retaining Ring
Figure 6-5. Clutch Assembly
2005 Touring: Drive
6-7
HOME
NOTE
Replace all nine friction plates with an entirely new set if any
Remove retaining ring from clutch hub.
individual plate shows evidence of wear or damage.
3. Check steel plates as follows:
● Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
● Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 inch (0.15 mm).
4. See Figure 6-5. Holding the clutch hub, rotate the clutch
shell to check bearing for smoothness. Replace the
bearing if it runs rough or binds.
5. Check the primary chain sprocket and the starter ring
gear on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.
f1519x6x
6. Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
Press clutch hub from bearing.
worn or damaged.
7. Check the diaphragm spring and diaphragm spring
retainer for cracks or bent tabs. Obtain a new diaphragm
spring or diaphragm spring retainer if either condition
exists.
COMPLETE DISASSEMBLY
CLUTCH PACK AND BEARING
1. Remove clutch assembly from the motorcycle. See Sec-
tion 6.5 PRIMARY CHAINCASE, REMOVAL, steps 1-16.
2. Remove six bolts to release diaphragm spring retainer
from clutch hub. See Figure 6-5.
3. Remove diaphragm spring retainer, diaphragm spring
and pressure plate from clutch hub.
4. Remove friction plates, steel plates, damper spring and
damper spring seat from clutch hub.
CAUTION
f1522x6x
To avoid possible bearing damage, do not disassemble
the clutch shell and hub assembly unless the bearing,
Figure 6-6. Remove Clutch Hub from Clutch Shell
hub or shell require replacement. Replace the bearing if
disassembled.
6.
Supporting clutch shell in same orientation, use arbor
press and a suitable press plug to press hub from bear-
1WARNING
ing in clutch shell. See lower frame of Figure 6-6.
Always wear proper eye protection when removing re-
7.
Turn clutch shell over so that the sprocket side is down.
taining rings. Use the correct retaining ring pliers. Verify
Remove retaining ring from groove in clutch shell bore.
that the tips of the pliers are not damaged or excessively
See upper frame of Figure 6-7.
worn. Slippage may propel the ring with enough force to
8.
Turn clutch shell over so that sprocket side is up. Using
cause eye injury.
arbor press and a suitable press plug, press on inner
5. With the sprocket side up, remove retaining ring from
race to remove bearing from clutch shell bore. See lower
clutch hub groove. See upper frame of Figure 6-6.
frame of Figure 6-7.
6-8
2005 Touring: Drive
HOME
Remove retaining ring from clutch shell.
1WARNING
Always wear proper eye protection when installing re-
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.
NOTE
Note that one side of the retaining ring is beveled. Always
install the ring with the beveled side opposite the bearing.
2.
Install retaining ring in groove of clutch shell bore, so
that the flat side of the ring is in towards the bearing, the
beveled side out.
3.
Center hub in bearing. Be sure that bearing inner race is
supported with sleeve on sprocket side. Press hub into
bearing until hub shoulder contacts bearing inner race.
f1521x6x
4.
Turn assembly over so that the sprocket side is up.
Install retaining ring in groove of clutch hub.
Press bearing from clutch shell.
5.
Place clutch assembly on bench oriented with the
sprocket side down.
6.
Submerge and soak all friction and steel plates in PRI-
MARY CHAINCASE LUBRICANT for at least five min-
utes.
7.
Install the narrow friction plate on the clutch hub engag-
ing tabs on plate with slots in clutch shell. See Figure 6-
8.
8.
Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.
9.
Install damper spring on clutch hub with the concave
side up (facing opposite damper spring seat). See Fig-
ure 6-4.
10.
Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
alternating between steel plates and friction plates.
Narrow Plate
f1520x6x
Figure 6-7. Remove Bearing from Clutch Shell
9. See CLEANING AND INSPECTION in this section.
ASSEMBLY
CLUTCH PACK AND BEARING
1. Orient clutch shell in arbor press with sprocket side
down. Be sure to support clutch shell bore on sprocket
f1513x6x
Regular Plate
side. Using a suitable press plug, press against outer
race until bearing contacts shoulder in clutch shell bore.
Figure 6-8. Friction Plates
2005 Touring: Drive
6-9
HOME
11. Install pressure plate on clutch hub aligning holes in
14. Install six bolts to secure diaphragm spring retainer to
plate with threaded bosses on hub.
clutch hub. Alternately tighten bolts to
90-110 in-lbs
(10.2-12.4 Nm).
12. Seat diaphragm spring in recess of pressure plate with
the concave side down.
15. Install clutch assembly on motorcycle. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION, steps 8-31.
13. Align holes in diaphragm spring retainer with threaded
bosses on clutch hub. Tabs on spring retainer contact
flats on inboard side of bosses.
6-10
2005 Touring: Drive
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SECONDARY DRIVE BELT AND SPROCKETS
6.4
ADJUSTMENT
DRIVE BELT/TRANSMISSION SPROCKET WEAR
See Section 1.10 DRIVE BELT.
Look for
Cracks Here
Sliding
High-Pressure
Contact Here
Drive Belt
CLEANING AND INSPECTION
Tensile Cords
1.
Use a spray solution of soap and water to clean belt.
Avoid immersion. Wipe the belt down or blow dry.
Worn Tooth
Although the belt's urethane compound is resistant to
Profile
most solvents, these should only be used on a limited
basis, and then must always be followed by a soap and
water wash.
2.
Inspect the edges of the belt for cuts or unusual wear
patterns. While some beveling of the outside edge is
common, and by itself is not usually harmful, it is an indi-
Transmission
Sprocket
cation of sprocket misalignment.
f1632x6x
3.
Inspect the outside ribbed surface of the belt for signs of
stone puncture. Since it is not always easy to observe
this type of damage, look closely.
DRIVE BELT WEAR
f1651x6x
4.
On the inside of the belt, inspect the roots of the belt
teeth to see if the tensile cords are exposed. See upper
frame of Figure 6-9. The tensile cords are covered by a
layer of nylon facing and another layer of polyethylene.
Once these layers are worn through, the tensile cords
Internal Tooth Crack
Pack Man Cracks
(Hairline)
Replace Belt
become visible. Visible tensile cords are an indication
OK to Run, But Monitor
that the transmission sprocket tooth tip diameter is
severely worn. Furthermore, belt failure is imminent,
since the tooth tips will continue to scratch away at the
tensile cords until the belt is completely worn through.
NOTE
During initial operation, the thin coating of polyethylene will
Missing Teeth
Chipping
wear off as it is burnished into the belt fabric. This is a normal
Replace Belt
(Not Serious)
OK to Run, But Monitor
condition and not an indication of belt wear.
5.
Look for signs of cracking at the base of the belt teeth
where contact may be made with the “corners” of worn
transmission sprocket teeth. See upper frame of Figure
6-9. Replace the belt if cracking is evident.
Fuzzy Edge Cord
Hook Wear
NOTE
(Not Serious)
Replace Belt
If the belt is replaced for reasons other than stone damage,
OK to Run, But Monitor
the transmission and/or rear wheel sprockets also should be
replaced. Use of worn or damaged sprockets will severely
Cross-Sectional View
affect belt service life.
6.
For common types of belt wear and damage, see lower
frame of Figure 6-9.
Stone Damage
Bevel Wear
Replace Belt
(Outboard Edge Only)
if Damage on Edge
OK to Run, But Monitor
Figure 6-9. Drive Belt/Transmission Sprocket Wear
2005 Touring: Drive
6-11
HOME
REPLACEMENT
INSTALLATION
CAUTION
REMOVAL
Handle the drive belt with care. Never bend belt forward
into a loop smaller than five inches (127 mm) diameter.
1.
Remove rear wheel and rear swingarm. See Section
Never bend belt into a reverse loop smaller than ten
2.20 REAR SWINGARM, REMOVAL.
inches (254 mm) diameter. Over bending will weaken belt
and result in premature failure. Always install belt in the
2. Remove the primary chaincase assembly. See Section
same direction of rotation as when it was removed. For
6.5 PRIMARY CHAINCASE, REMOVAL.
other handling tips, see Figure 6-10.
3. Remove the old belt from the transmission sprocket.
1.
Install the new belt on the transmission sprocket.
Forward bend must not be less than 5 in. (127 mm).
Reverse bend must not be less than 10 in. (254 mm).
A
B
Minimum Diameter
Minimum Diameter
Do not twist.
Do not crimp, pinch or kink.
C
D
Do not pry.
E
CAUTION
Mishandling drive belt will result in premature failure.
For maximum strength, integrity and longevity, avoid
over bending (A and B), twisting (C), crimping, pinch-
ing or kinking (D), and prying (E).
Figure 6-10. Proper Drive Belt Handling
6-12
2005 Touring: Drive
HOME
2. Install the primary chaincase assembly. See Section 6.5
2. Carefully inspect the sprocket for cracks or other dam-
PRIMARY CHAINCASE, INSTALLATION.
age.
3. Install rear swingarm and rear wheel. Adjust belt deflec-
3. Inspect the sprocket for heavy pitting, which indicates a
tion. See Section 2.20 REAR SWINGARM, INSTALLA-
high degree of abrasive wear.
TION.
4. Look for “sharp” corners at the top of each sprocket
tooth, particularly where the flank joins the top radius. A
smooth transition should exist between the flank and
radius. While worn teeth will appear to have an edge
TRANSMISSION SPROCKET
across the face width of the tooth, heavily worn teeth will
have a flat across the top. If the flat is 1/8 inch (3 mm)
wide or more, replace the transmission sprocket and
REMOVAL
drive belt. See upper frame of Figure 6-9.
1. Remove rear wheel. See Section 2.4 REAR WHEEL,
REMOVAL.
2. Remove the primary chaincase assembly. See Section
INSTALLATION
6.5 PRIMARY CHAINCASE, REMOVAL.
1.
Install the transmission sprocket (with belt) on the main
3. See Figure 6-11. Remove the two socket screws and
drive gear.
lockplate to free the sprocket nut.
2.
Install the sprocket nut. The following procedure is based
NOTE
on whether a new or used nut is being installed.
The transmission sprocket nut has left handed threads. Turn
the nut clockwise to remove from the main drive gear.
CAUTION
4. Remove the sprocket nut. Use an air impact wrench for
Exercise caution to avoid getting oil on the threads of
best results.
the sprocket nut or the integrity of the lock patch may be
compromised.
CLEANING AND INSPECTION
New sprocket nut: smear a small quantity of clean
engine oil on the inside face of the sprocket nut and the
1. Using a non-volatile cleaning solvent, thoroughly clean
outside face of the sprocket. Limit the application to
the transmission sprocket of all grease and dirt.
where the surfaces of the two parts contact each other.
Install the sprocket nut until finger tight.
NOTE
The transmission sprocket nut has left handed threads. Turn
2
the nut counterclockwise to install on the main drive gear.
4
Used sprocket nut: apply Loctite High Strength Thread-
7
6
locker 262 (red) to the threads of the sprocket nut. Also
smear a small quantity of Loctite or clean engine oil on
the inside face of the sprocket nut and the outside face
1
of the sprocket. Limit the application to where the sur-
3
faces of the two parts contact each other. See Figure 6-
11. Install the sprocket nut until finger tight.
5
Lubricate
8
3. Obtain FINAL DRIVE SPROCKET LOCKING TOOL
f1172a6x
Contact Surfaces
(HD-41184) to lock transmission sprocket. See Figure 6-
12. Proceed as follows:
1. Main Drive Gear
5. Transmission Sprocket
a. Insert handle of tool below pivot shaft inboard of
2. Large Oil Seal
6. Sprocket Nut
bottom frame tube and attach to sprocket. See
3. Quad Seal
7. Lockplate
upper frame of Figure 6-13.
4. Spacer
8. Socket Screw (2)
b. Snug thumbscrew to lock position of tool on
Figure 6-11. Install Transmission Sprocket Components
sprocket. See lower frame of Figure 6-13.
2005 Touring: Drive
6-13
HOME
a. Install pilot on threaded end of mainshaft. See
upper frame of Figure 6-15.
b. Slide sleeve of locknut wrench over pilot and onto
sprocket nut.
c. Tighten sprocket nut to 60 ft-lbs (81 Nm). See lower
frame of Figure 6-15. As the nut is tightened the
handle of the sprocket locking tool rises to contact
the pivot shaft, thereby preventing sprocket/main-
shaft rotation.
Figure 6-12. Final Drive Sprocket Locking Tool
5.
Scribe a straight line on the transmission sprocket nut
(Part No. HD-41184)
continuing the line over onto the transmission sprocket
as shown in Figure
6-16. Tighten the transmission
Transmission
sprocket nut an additional 35° to 40°.
Sprocket
6.
Install lockplate over nut so that two diagonally opposite
holes align with two tapped holes in sprocket. To find the
best fit, lockplate can be rotated to a number of positions
and can be placed with either side facing sprocket.
7.
If holes in lockplate do not align with those in sprocket,
tighten sprocket nut as necessary (up to the 45° maxi-
mum) until sprocket and lockplate holes are in align-
ment. See Figure 6-16.
CAUTION
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation after a torque of 60 ft-lbs (81
Nm). Do not loosen sprocket nut to align holes or nut will
be under tightened.
Sprocket
Locking Tool
f1855x7x
8.
Insert two socket head screws through lockplate into
sprocket holes. Tighten screws to 84-108 in-lbs (9.5-
Pivot Shaft
f1856x7x
12.2 Nm).
NOTE
The socket head screws have a thread locking compound
that allows them to be reused up to three times. The fourth
time the screws are removed, replace with new screws (H-D
Part No. 3594).
9.
Install primary chaincase assembly. See Section
6.5
PRIMARY CHAINCASE, INSTALLATION.
10. Install rear wheel and adjust belt deflection. See Section
2.4 REAR WHEEL, INSTALLATION.
REAR WHEEL SPROCKET
Sprocket
Thumbscrew
Nut
REMOVAL
Figure 6-13. Install Final Drive Sprocket Locking Tool
1. Remove rear wheel. See Section 2.4 REAR WHEEL,
REMOVAL.
4.
Obtain MAINSHAFT LOCKNUT WRENCH/PILOT (HD-
2. Remove five bolts with flat washers securing sprocket to
94660-37B). See Figure 6-14. Proceed as follows:
hub.
6-14
2005 Touring: Drive
HOME
f1977x6x
Wrench
Sprocket Nut
Pilot
45°
35°
Figure 6-14. Mainshaft Locknut Wrench/Pilot
(Part No. HD-94660-37B )
Scribe Line
Transmission
on Nut and Sprocket
Sprocket
Figure 6-16. Tighten/Secure Sprocket Nut
2.
Carefully inspect the sprocket for cracks or other dam-
age.
3.
Inspect each sprocket tooth for large chrome chips hav-
ing sharp edges. Look for gouges caused by contact
with a hard object. If large enough, both of these condi-
tions will leave a corresponding pattern in the belt face
Sprocket
and are cause for rear sprocket replacement.
Pilot
f1857x7x
Nut
4.
Without obvious damage, rear wheel sprocket replace-
f1858x7x
Mainshaft
ment may be a subjective decision based on general
Locknut
appearance. Using medium pressure, drag a scribe or
Wrench
the sharp point of a knife blade across the root of a
groove. Even though the plating is lightest in the root
area, a knife point should not penetrate the chrome. If
the blade slides across the chrome plating without dig-
ging in, then the chrome is still good. On the other hand,
if you can feel the scribe digging in and it leaves a visible
mark, then the chrome plating has worn off and the bare
aluminum is being cut. Loss of chrome is cause for rear
sprocket replacement.
INSTALLATION
Torque
Wrench
1.
Apply two drops of Loctite High Strength Threadlocker
271 (red) to threads of each of five sprocket bolts.
Figure 6-15. Install Mainshaft Locknut Pilot/Wrench
Secure sprocket to hub using bolts with flat washers
and Torque Sprocket Nut
(and locknuts on laced wheels). Tighten bolts to
55-65 ft-lbs (75-88 Nm).
2.
Install rear wheel and adjust belt deflection. See Section
2.4 REAR WHEEL, INSTALLATION.
CLEANING AND INSPECTION
1.
Using a non-volatile cleaning solvent, thoroughly clean
the rear wheel sprocket of all grease and dirt.
2005 Touring: Drive
6-15
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