Harley Davidson 2004 Touring Models. Service Manual — page 46
HOME
6.
If belt is too tight, move to step 7 to increase belt deflec-
tion. If belt is too loose, reduce belt deflection as
CAUTION
described below:
Verify that the exhaust pipes do not contact the vehicle
a. Rotate weld nut on left side of axle in a clockwise
frame or any mounted components. Contact will cancel
direction.
the effect of the rubber isolation mounts and transmit
b. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
vibration to the rider via the vehicle frame.
at the midpoint of the bottom belt strand. Belt
d. Verify that exhaust pipes are in alignment and do
deflection should be within the range specified in
not contact the motorcycle frame or mounted com-
Table 6-3.
ponents.
c. If belt is still too loose, repeat steps 6(a) through
e. Tighten the TORCA clamp to 45-60 ft-lbs (61-81
6(b). If belt is now too tight, move to step 7.
Nm).
7.
If belt is too tight, increase belt deflection as follows:
f.
Open worm drive clamps and install heat shield on
a. Using a hydraulic center stand, raise motorcycle so
rear header pipe. Position clamp so that screw is on
that the rear wheel is off the ground.
the outboard side in the most accessible position.
b. Rotate weld nut on left side of axle in a counter-
clockwise direction.
CAUTION
c. Push wheel forward slightly so that adjuster cam
Verify that the heat shields do not contact the vehicle
just contacts weld nub on both sides of rear swing-
frame or any mounted components. Contact will cancel
arm. See Figure 6-14.
the effect of the rubber isolation mounts and transmit
d. Check belt deflection. Apply 10 lbs. (4.5 kg) of force
vibration to the rider via the vehicle frame.
at the midpoint of the bottom belt strand. Belt
g. Remove bungee cord from muffler.
deflection should be within the range specified in
Table 6-3.
12. Install saddlebags. See Section
2.25 SADDLEBAG,
e. If belt is still too tight, repeat steps 7(b) through 7(d).
INSTALLATION.
If belt is now too loose, move to step 6.
8.
Holding weld nut on left side of axle, tighten cone nut on
CLEANING AND INSPECTION
right side to 95-105 ft-lbs (128.8-142.4 Nm).
1.
Use a spray solution of soap and water to clean belt.
NOTE
Avoid immersion. Wipe the belt down or blow dry.
If the axle moves during tightening of the cone nut, then the
Although the belt's urethane compound is resistant to
the belt deflection procedure must be restarted.
most solvents, these should only be used on a limited
9. Recheck belt deflection to verify that it is still within spec-
basis, and then must always be followed by a soap and
ification.
water wash.
If the belt deflection is not within specification, loosen
2.
Inspect the edges of the belt for cuts or unusual wear
cone nut and then snug to 15-20 ft-lbs (20-27 Nm)
patterns. While some beveling of the outside edge is
before returning to step 6.
common, and by itself is not usually harmful, it is an indi-
10. With the flat side out, install new E-clip in groove on right
cation of sprocket misalignment.
side of axle.
3.
Inspect the outside ribbed surface of the belt for signs of
11. Install right side muffler as follows:
stone puncture. Since it is not always easy to observe
this type of damage, look closely.
NOTE
TORCA muffler clamps have eliminated the need for silicone
4.
On the inside of the belt, inspect the roots of the belt
or graphite tape during assembly. To ensure sealing integrity
teeth to see if the tensile cords are exposed. See upper
of muffler clamps and prevent the possibility of leakage, Har-
frame of Figure 6-15. The tensile cords are covered by a
ley-Davidson recommends that TORCA clamp assemblies be
layer of nylon facing and another layer of polyethylene.
Once these layers are worn through, the tensile cords
discarded and replaced each time they are removed.
become visible. Visible tensile cords are an indication
a. Slide new TORCA clamp onto free end of rear
that the transmission sprocket tooth tip diameter is
header pipe.
severely worn. Furthermore, belt failure is imminent,
b. Using a bungee cord, tie muffler to lower saddlebag
since the tooth tips will continue to scratch away at the
support rail. Install muffler on rear header pipe.
tensile cords until the belt is completely worn through.
Place TORCA clamp into position between rear
NOTE
header pipe and muffler.
During initial operation, the thin coating of polyethylene will
c. Tighten the two bolts (with lockwashers) to fasten
wear off as it is burnished into the belt fabric. This is a normal
the muffler to the lower saddlebag support rail.
condition and not an indication of belt wear.
6-14
2004 Touring: Drive
HOME
5.
Look for signs of cracking at the base of the belt teeth
DRIVE BELT/TRANSMISSION SPROCKET WEAR
where contact may be made with the “corners” of worn
transmission sprocket teeth. See upper frame of Figure
Look for
6-15. Replace the belt if cracking is evident.
Cracks Here
Sliding
High-Pressure
Contact Here
NOTE
Drive Belt
If the belt is replaced for reasons other than stone damage,
the transmission and/or rear wheel sprockets also should be
replaced. Use of worn or damaged sprockets will severely
affect belt service life.
Tensile Cords
6.
For common types of belt wear and damage, see lower
Worn Tooth
Profile
frame of Figure 6-15.
REPLACEMENT
Transmission
Removal
Sprocket
f1632x6x
1. Remove rear wheel and rear swingarm. See Section
2.20 REAR SWINGARM, REMOVAL.
2. Remove the primary chaincase assembly. See Section
DRIVE BELT WEAR
f1651x6x
6.5 PRIMARY CHAINCASE, REMOVAL.
3. Remove the old belt from the transmission sprocket.
Installation
Internal Tooth Crack
Pack Man Cracks
(Hairline)
Replace Belt
OK to Run, But Monitor
CAUTION
Handle the drive belt with care. Never bend belt forward
into a loop smaller than five inches (127 mm) diameter.
Never bend belt into a reverse loop smaller than ten
inches (254 mm) diameter. Over bending will weaken belt
and result in premature failure. Always install belt in the
Missing Teeth
Chipping
same direction of rotation as when it was removed. For
Replace Belt
(Not Serious)
OK to Run, But Monitor
other handling tips, see Figure 6-16.
1.
Install the new belt on the transmission sprocket.
2.
Install the primary chaincase assembly. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION.
3.
Install rear swingarm and rear wheel. Adjust belt deflec-
tion. See Section 2.20 REAR SWINGARM, INSTALLA-
Fuzzy Edge Cord
Hook Wear
(Not Serious)
Replace Belt
TION.
OK to Run, But Monitor
Cross-Sectional View
TRANSMISSION SPROCKET
Stone Damage
Bevel Wear
Removal
Replace Belt
(Outboard Edge Only)
if Damage on Edge
1.
Remove rear wheel. See Section 2.4 REAR WHEEL,
OK to Run, But Monitor
REMOVAL.
2.
Remove the primary chaincase assembly. See Section
Figure 6-15. Drive Belt/Transmission Sprocket Wear
6.5 PRIMARY CHAINCASE, REMOVAL.
2004 Touring: Drive
6-15
HOME
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 6-16. Proper Drive Belt Handling
3.
See Figure 6-17. Remove the two socket screws and
3.
Inspect the sprocket for heavy pitting, which indicates a
lockplate to free the sprocket nut.
high degree of abrasive wear.
4.
Look for “sharp” corners at the top of each sprocket
NOTE
tooth, particularly where the flank joins the top radius. A
The transmission sprocket nut has left handed threads. Turn
smooth transition should exist between the flank and
the nut clockwise to remove from the main drive gear.
radius. While worn teeth will appear to have an edge
4.
Remove the sprocket nut. Use an air impact wrench for
across the face width of the tooth, heavily worn teeth will
best results.
have a flat across the top. If the flat is 1/8 inch (3 mm)
wide or more, replace the transmission sprocket and
drive belt. See upper frame of Figure 6-15.
Cleaning and Inspection
1.
Using a non-volatile cleaning solvent, thoroughly clean
Installation
the transmission sprocket of all grease and dirt.
2.
Carefully inspect the sprocket for cracks or other dam-
1. Install the transmission sprocket (with belt) on the main
age.
drive gear.
6-16
2004 Touring: Drive
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Main Drive
Gear
Mainshaft
Oil Seal
Spacer
Sleeve
Lockplate
Sprocket
Nut
Figure 6-18. Final Drive Sprocket Locking Tool
Quad Seal
(Part No. HD-41184)
Transmission
Sprocket
Transmission
Lubricate
Sprocket
Contact Surfaces
Socket
Screw
f1172a6x
Figure 6-17. Transmission Sprocket Components
2. To install the sprocket nut, follow the appropriate proce-
dure based on whether a new or used nut is being
installed.
CAUTION
Exercise caution to avoid getting oil on the threads of
the sprocket nut or the integrity of the lock patch may be
compromised.
New sprocket nut: smear a small quantity of clean
Sprocket
engine oil on the inside face of both the sprocket nut and
Locking Tool
f1855x7x
the sprocket. Limit the application to where the surfaces
of the two parts contact each other. Install the sprocket
Pivot Shaft
f1856x7x
nut until finger tight.
NOTE
The transmission sprocket nut has left handed threads. Turn
the nut counterclockwise to install.
Used sprocket nut: apply Loctite High Strength Thread-
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 both the sprocket nut and the sprocket.
Limit the application to where the surfaces of the two
parts contact each other. Install the sprocket nut until fin-
ger tight.
3. Lock transmission sprocket with the FINAL DRIVE
SPROCKET LOCKING TOOL (Part No. HD-41184). See
Figure 6-18.
Insert handle of tool below pivot shaft inboard of bottom
Sprocket
Sprocket
Nut
frame tube and attach to sprocket. Snug thumbscrew to
Locking Tool
lock position of tool on sprocket. See Figure 6-19.
Figure 6-19. Install Final Drive Sprocket Locking Tool
4. Install pilot of MAINSHAFT LOCKNUT WRENCH (Part
No. HD-94660-37B) on threaded end of mainshaft. See
Figure 6-20. Slide sleeve of locknut wrench over pilot
and onto sprocket nut. Tighten sprocket nut to 60 ft-lbs
5.
Scribe a straight line on the transmission sprocket nut
(81 Nm). As the nut is tightened the handle of the
continuing the line over onto the transmission sprocket
sprocket locking tool rises to contact the pivot shaft,
as shown in Figure
6-22. Tighten the transmission
sprocket nut an additional 35° to 40°.
thereby preventing sprocket/mainshaft rotation. See Fig-
ure 6-21.
2004 Touring: Drive
6-17
HOME
7. If holes in lockplate do not align with those in sprocket,
tighten sprocket nut as necessary (up to the 45° maxi-
Wrench
mum) until sprocket and lockplate holes are in align-
ment. See Figure 6-22.
CAUTION
Maximum allowable tightening of sprocket nut is 45° of
Pilot
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.
Figure 6-20. Mainshaft Locknut Wrench/Pilot
8.
Insert two socket head screws through lockplate into
(Part No. HD-94660-37B )
sprocket holes. Tighten screws to 90-110 in-lbs (10-12
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
Pilot
f1857x7x
Nut
f1858x7x
Mainshaft
Removal
Locknut
Wrench
1. Remove rear wheel. See Section 2.4 REAR WHEEL,
REMOVAL.
2.
Remove five bolts with flat washers securing sprocket to
hub.
f1977x6x
Sprocket Nut
Torque
Wrench
45°
Figure 6-21. Install Mainshaft Locknut Pilot/Wrench
35°
and Torque Sprocket Nut
Scribe Line
Transmission
6.
Install lockplate over nut so that two diagonally opposite
on Nut and Sprocket
Sprocket
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.
Figure 6-22. Tighten/Secure Sprocket Nut
6-18
2004 Touring: Drive
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Cleaning and Inspection
Installation
1. Using a non-volatile cleaning solvent, thoroughly clean
1.
Apply two drops of Loctite High Strength Threadlocker
the rear wheel sprocket of all grease and dirt.
271 (red) to threads of each of five sprocket bolts.
Secure sprocket to hub using bolts with flat washers
2. Carefully inspect the sprocket for cracks or other dam-
(and locknuts on laced wheels). Tighten bolts to
age.
55-65 ft-lbs (75-88 Nm).
3. Inspect each sprocket tooth for large chrome chips hav-
ing sharp edges. Look for gouges caused by contact
2.
Install rear wheel and adjust belt deflection. See Section
with a hard object. If large enough, both of these condi-
2.4 REAR WHEEL, INSTALLATION.
tions will leave a corresponding pattern in the belt face
and are cause for rear sprocket replacement.
4. Without obvious damage, rear wheel sprocket replace-
ment may be a subjective decision based on general
appearance. Using medium pressure, drag a scribe or
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.
2004 Touring: Drive
6-19
HOME
PRIMARY CHAINCASE
6.5
GENERAL
Primary
Chaincase Cover
The primary chaincase is a sealed housing containing the
primary chain, clutch, engine compensating sprocket, chain
tensioner assembly, alternator and starter drive mechanism.
LUBRICATION
At the 1000 mile (1600 km) service interval, and at every
5000 mile (8000 km) service interval thereafter, change the
primary chaincase lubricant as follows:
1.
Using a T27 TORX drive head, remove five screws (with
captive washers) to free clutch inspection cover from pri-
mary chaincase cover.
Lubricant
2.
Remove magnetic drain plug at bottom of primary chain-
f1508b6x
case cover. Drain lubricant into suitable container. See
Figure 6-23.
Figure 6-24. Fill Primary Chaincase With Lubricant
3.
Clean drain plug. If plug has accumulated a lot of debris,
inspect the condition of chaincase components.
CAUTION
4.
Inspect drain plug O-ring for cuts, tears or signs of dete-
Do not overfill the primary chaincase with lubricant.
rioration. Replace as necessary.
Overfilling may cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
5.
Install drain plug back into primary chaincase cover.
finding neutral at engine idle.
Tighten plug to 36-60 in-lbs (4.1-6.8 Nm).
7.
Remove quad ring from groove in primary chaincase
6.
Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY
cover. Wipe all lubricant from the quad ring and inspect
CHAINCASE LUBRICANT through the clutch inspection
for cuts, tears or signs of deterioration. Replace as nec-
cover opening, Part No. 99887-84 (quart) or Part No.
essary.
99886-84 (gallon). See Figure 6-24.
8.
Swab all lubricant from the quad ring groove. Install
quad ring in primary chaincase cover with the nubs con-
tacting the ring groove walls.
f1210x6x
NOTE
If lubricant is not thoroughly removed from both the quad ring
and groove, compression of the ring during installation of the
clutch inspection cover can cause lubricant to be squeezed
1
to the outboard side of the ring groove, resulting in some
1
4
Clutch
3
temporary weepage around the inspection cover.
4
Inspection
Cover
Primary
9.
Using a T27 TORX drive head, install five screws (with
Chain
2
5
captive washers) to secure clutch inspection cover to the
Inspection
Cover
primary chaincase cover. Alternately tighten screws to
2
3
84-108 in-lbs (10-12 Nm) in the pattern shown in Figure
6-23.
Drain Plug
REMOVAL
Figure 6-23. Primary Chaincase Cover
1.
Remove seat. See Section 2.24 SEAT, REMOVAL.
6-20
2004 Touring: Drive
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8.
Remove ten allen head socket screws (with captive
f1840x6x
washers) from primary chaincase cover. Remove pri-
mary chaincase cover from motorcycle.
Top Center Nut
9.
Loosen top center nut from captured bolt of chain ten-
sioner assembly. See Figure 6-25. Lower the chain ten-
sioner assembly as required, so that the adjuster shoe
rests flat on casting of primary chaincase.
Primary
Chain
1WARNING
Always wear proper eye protection when removing 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.
10.
Remove retaining ring and pull release plate (with lock-
nut and adjuster screw) from clutch hub. See Figure 6-
Adjuster
Shoe
26.
11.
Obtain the PRIMARY DRIVE LOCKING TOOL (HD-
Figure 6-25. Chain Tensioner Assembly
41214). See Figure 6-27.
With the flat side against the upper strand of the primary
chain, insert stepped side of tool into teeth of engine
1WARNING
compensating sprocket. Using a breaker bar and 1-1/2
inch socket, turn the sprocket nut in a counterclockwise
To protect against shock and accidental start-up of vehi-
direction. Once the stepped area of the tool is drawn into
cle, disconnect the negative battery cable before pro-
the sprocket, rotation of the primary drive is stopped.
ceeding. Inadequate safety precautions could result in
Continue turning sprocket nut until loose. See Figure 6-
death or serious injury.
28.
2.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3.
Standing on left side of motorcycle, remove magnetic
drain plug at bottom of primary chaincase cover. Drain
lubricant into suitable container.
NOTE
If drain plug has accumulated a lot of debris, inspect the con-
dition of chaincase components.
Adjuster
4.
Remove socket screw with lockwasher to remove pas-
Screw
senger footboard from rear swingarm bracket.
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
Locknut
stand bracket, remove lower hex bolt (with lockwasher)
and upper hex bolt (with lockwasher and locknut).
Release
6.
Remove locknut, lockwasher and flat washer to free
Plate
shifter rod from front inboard shifter lever.
Retaining
Ring
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/
lever assembly from primary chaincase bore. When pull-
f1509b6x
ing any lever from splined shaft, always mark splines on
both shaft and lever to assist in assembly.
Figure 6-26. Clutch
Hub Release Plate Assembly
2004 Touring: Drive
6-21
HOME
NOTE
If too much loctite, or perhaps the wrong loctite, was used to
f1208axx
Alternator Rotor Spacer
install the engine compensating sprocket nut, it may be very
Low Output Rotor Only - 0.020 In.
difficult to remove. In these cases, break down loctite using
heat from a small propane torch. Apply heat evenly around
Compensating
nut head in a circular motion, but not for so long as to turn nut
Sprocket
blue. Do not direct heat at chain tensioner assembly and
Sprocket
other components or damage will result. If unable to loosen
Cover
sprocket nut with breaker bar after applying heat, use air
impact wrench as the last alternative.
Shaft
1WARNING
Extension
Use extreme caution when operating propane torch.
Read the manufacturers instructions carefully before
Sliding
use. Do not direct open flame or heat toward any fuel
Cam
system component. Extreme heat can cause fuel ignition
Compensating
and explosion. Inadequate safety precautions could
Sprocket Nut
result in death or serious injury.
12. Reverse the position of the primary drive locking tool.
Figure 6-29. Engine Compensating Sprocket Assembly
With the flat side against the upper strand of the primary
chain, insert stepped side of tool into teeth of clutch
NOTE
sprocket. Using a breaker bar and 1-3/16 inch socket,
Clutch hub mainshaft nut has left handed threads.
turn the clutch hub mainshaft nut in a clockwise direction
13. Remove the primary drive locking tool. Remove the
until loose. See Figure 6-30.
clutch hub mainshaft nut and engine compensating
sprocket nut.
14. Remove sprocket cover and sliding cam. See Figure 6-
29.
CAUTION
15. Remove clutch, primary chain, compensating sprocket
Do not place the tool on the
lower strand of the primary
and shaft extension as a single assembly. See Figure 6-
chain. Rotation of either the com-
31.
pensating sprocket nut or clutch
hub nut causes tool to exert
16. Remove the alternator rotor spacer from the engine
enough force to break or shatter
sprocket shaft, if present.
the nylon adjuster shoe.
NOTE
The alternator rotor spacer is only present on those vehicles
Figure 6-27. Primary Drive Locking Tool
with the 38 amp low output rotor.
(Part No. HD-41214)
7859
7856
Primary Drive
Locking Tool
Primary Drive
Locking Tool
Breaker
Breaker
Bar
Bar
Figure 6-28. Place Primary Drive Locking Tool
Figure 6-30. Place Primary Drive Locking Tool
and Loosen Compensating Sprocket Nut
and Loosen Clutch Hub Mainshaft Nut
6-22
2004 Touring: Drive
HOME
coatings into the steel backing). Replace the lip seal.
7943
See STARTER JACKSHAFT BUSHING AND LIP SEAL
Compensating
- PRIMARY CHAINCASE in this section.
Sprocket
4.
Check the shifter bracket bushings in the primary chain-
case. Replace the bushings if necessary. See SHIFTER
BRACKET BUSHINGS in this section.
Primary
DISASSEMBLY
Chain
MAINSHAFT BEARING AND LIP SEAL
Shaft
Extension
Clutch
REMOVAL
Assembly
Figure 6-31. Remove Clutch Assembly, Primary Chain,
1WARNING
Compensating Sprocket and Shaft Extension
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
17. Bend tab on lockplate away from head of jackshaft bolt.
worn. Slippage may propel the ring with enough force to
Holding pinion gear to prevent rotation, remove the jack-
cause eye injury.
shaft bolt with lockplate and thrust washer. Carefully pull
jackshaft assembly from primary chaincase bore.
1.
Remove retaining ring from groove on clutch side of pri-
mary chaincase. Turn the chaincase over to transmis-
18. From right side of motorcycle, remove starter front
sion side.
mounting screw with lockwasher. Remove rear mounting
screw with lockwasher, but do not disconnect chassis
2.
Pull lip seal from bearing bore on transmission side of
ground cable ring terminal.
primary chaincase. Use a seal remover or rolling head
19. Returning to left side of motorcycle, remove two bolts
pry bar for best results. Remove retaining ring from
groove on same side of chaincase.
(with flat washers) from outside edge of primary chain-
case.
20. Using a chisel and hammer, bend tabs on lockplates
CAUTION
away from heads of 5 inside bolts. Remove bolts (with
Failure to provide proper support will cause the casting
lockplates) to free primary chaincase from crankcase
to crack or break around the outside diameter of the
and transmission housings. Remove primary chaincase
boss. Any damage to the casting requires replacement
from motorcycle.
of the primary chaincase.
21. Remove O-ring from crankcase lip and discard.
3.
Place primary chaincase in arbor press with the trans-
mission side up. Be sure to properly support boss on
clutch side to avoid damage to casting.
INSPECTION AND REPAIR
4.
Center bearing under ram, and using a suitable driver,
carefully press out bearing applying pressure to the
1. Inspect the primary chaincase for cracks or other dam-
outer race.
age. Replace as necessary.
2. Check the mainshaft bearing. Bearing must rotate freely
without drag. Replace the bearing if necessary. Replace
INSTALLATION
the lip seal. See MAINSHAFT BEARING AND LIP SEAL
on this page.
1.
Inspect the bearing bore to verify that it is clean and
smooth.
NOTE
Also check the bearing inner race on the mainshaft. Replace
the race if scored or excessively worn. See MAINSHAFT
1WARNING
BEARING INNER RACE in this section.
Always wear proper eye protection when installing re-
3. Check the starter jackshaft bushing in the primary chain-
taining rings. Use the correct retaining ring pliers. Verify
case. Check the jackshaft bushing in the primary chain-
that the tips of the pliers are not damaged or excessively
case cover. Replace the bushings if they are damaged
worn. Slippage may propel the ring with enough force to
or excessively worn (i.e., through the teflon and copper
cause eye injury.
2004 Touring: Drive
6-23
HOME
4.
Place primary chaincase in arbor press with the clutch
f1216x6x
side up. Be sure to properly support boss on transmis-
sion side to avoid damage to casting.
5.
Place bearing over bore with the lettered side up. Center
bearing under ram, and using a suitable driver, apply
pressure to the outer race until bearing makes contact
with the installed retaining ring.
6.
Install second retaining ring to lock position of bearing in
bore on clutch side of chaincase. Verify that retaining
ring is fully seated in the groove.
7.
Turn chaincase over, so that the transmission side is up.
With the open (lip garter spring) side facing the bearing,
press fit a new lip seal into the bore until it makes con-
tact with the installed retaining ring. Be sure to support
Figure 6-32. Mainshaft Bearing Inner Race Remover
bearing outer race on clutch side during the press proce-
(Part No. HD-34902B)
dure. Verify that seal is square in the bore and com-
pletely seated around its circumference.
f1217x7x
8.
Lubricate the bearing and lip seal with multi-purpose
grease or clean H-D 20W50 engine oil.
MAINSHAFT BEARING INNER RACE
Bearing
NOTE
Inner Race
The bearing inner race must be properly positioned on the
Mainshaft
mainshaft to align with the bearing outer race in the primary
Plug
chaincase. To remove and install the bearing inner race, use
the combination MAINSHAFT BEARING INNER RACE
Bridge
REMOVER/INSTALLER, Part No. HD-34902B. See Figure 6-
32 and Figure 6-34.
REMOVAL
1.
Install small flat washers on two long bolts of puller tool.
Slide one bolt into channel on each side of bridge so that
washer is between bridge and bolt head. Thread bolts
Puller
Long
Plate
Bolt
into stamped side of U-shaped puller plate an equal
Flat
number of turns.
Washer
2.
Sparingly apply graphite lubricant to threads of forcing
Forcing
screw to ensure smooth operation. Thread forcing screw
Screw
into center hole of bridge.
3.
Position U-shaped puller plate between bearing inner
Figure 6-33. Pull Mainshaft Bearing Inner Race
race and sprocket nut. See Figure 6-33.
4.
Install mainshaft plug into end of transmission main-
shaft. Thread the forcing screw into the bridge until the
2.
Install retaining ring in groove on transmission side of
steel ball at the end of the screw seats in the cavity of
primary chaincase. Verify that the retaining ring is fully
the mainshaft plug. Verify that the tool assembly is
seated in the groove.
square so that the bearing is not cocked during removal.
3.
Apply a thin film of clean H-D 20W50 engine oil to bear-
5.
Continue turning the forcing screw until the bearing inner
ing bore and O.D. of new bearing.
race is pulled free of the mainshaft.
CAUTION
INSTALLATION
Failure to provide proper support will cause the casting
1.
See Figure 6-35. Chamfered edge first, slide the bearing
to crack or break around the outside diameter of the
boss. Any damage to the casting requires replacement
inner race onto the transmission mainshaft.
of the primary chaincase.
2.
Thread extension shaft onto end of mainshaft.
6-24
2004 Touring: Drive
HOME
NOTE
f1215x6x
Extension shaft has left handed threads, so turn counter-
clockwise to install.
3.
See Figure 6-35. 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
extension shaft until they contact installer tube. Install
large hex nut onto extension shaft.
5.
With a wrench on flats at threaded end of extension
Figure 6-34. Mainshaft Bearing Inner Race Installer
shaft, hold shaft stationary while turning hex nut in a
(Part No. HD-34902B)
clockwise direction. In this manner, press race onto shaft
so inside edge is 0.100 in. (2.54 mm) from main drive
gear.
Install Inner Race
6.
Lubricate the race with multi-purpose grease or clean
and Extension Shaft
engine oil.
STARTER JACKSHAFT BUSHING
Extension
AND LIP SEAL - PRIMARY CHAINCASE
Shaft
REMOVAL
1.
Remove bushing from jackshaft bore of primary chain-
case. For best results, use a bushing/bearing puller with
expandable collet and slide hammer.
Wrench
2.
Remove lip seal from bore.
Flat
INSTALLATION
1.
Inspect the bushing bore to verify that it is clean and
Bearing
Inner Race
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.
2.
With the open (lip garter spring) side facing up, press fit
a new lip seal into the jackshaft bore until it makes solid
Install Tube, Flat Washers
contact with the shoulder on the transmission side. Verify
and Hex Nut
that the seal is square in the bore and completely seated
around its circumference.
3.
See Figure 6-36. 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 and seal lip with multi-purpose
grease or clean engine oil.
Flat
Washers
STARTER JACKSHAFT BUSHING -
PRIMARY CHAINCASE COVER
REMOVAL
1.
Remove bushing from jackshaft bore of primary chain-
Installer
case cover. For best results, use a bushing/bearing
Tube
Hex
puller with expandable collet and slide hammer.
f1218x7x
Nut
2.
Inspect the bushing bore to verify that it is clean and
smooth.
Figure 6-35. Press Bearing Inner Race onto Mainshaft
2004 Touring: Drive
6-25
HOME
SHIFTER BRACKET BUSHINGS
f1212a6x
Press Bushing Flush
With Boss or to a
REMOVAL
Maximum Depth of
Bushing
Primary
0.010 In. (0.25 mm)
1.
Remove spacer and shifter shaft assembly from shifter
Chaincase
bracket bore of primary chaincase.
2.
Using an arbor press, press bushings from bore. Inspect
the bushing bore to verify that it is clean and smooth.
INSTALLATION
1.
Place primary chaincase in arbor press.
2.
Press new bushing into each end of bore. Installed
Lip Seal
bushings must be flush to 0.010 inch (0.76 mm) above
outer edge of bore.
Press Lip Seal
3.
Install shifter shaft in shifter bracket bore. Install spacer
Transmission
Against Shoulder
on shifter shaft.
Side
4.
Assemble primary chaincase. See Section
6.5 PRI-
Figure 6-36. Install Jackshaft Seal and Bushing in
MARY CHAINCASE, INSTALLATION, on the next page.
Primary Chaincase
INSTALLATION
1.
Using a T27 TORX drive head, remove five screws (with
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.
6-26
2004 Touring: Drive
HOME
8
f1048x6x
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
1
24
3.
Bolt (3), 5/16-18 x 3 in.
4.
Hole
19
5.
Lockplate (5)
22
23
6.
Bolt (4), 5/16-18 x 1-3/4 in.
7.
Primary chaincase
15
8.
Lip seal
9.
Retaining ring (2)
15. Primary chain inspection cover
21.
Screw, cover (5)
10.
Bearing, mainshaft
16. Quad ring
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 6-37. Primary Chaincase Assembly
Also apply the silicone sealer to the threads of the five
INSTALLATION
fasteners installed in these holes.
1. Install new O-ring on lip of crankcase.
CAUTION
CAUTION
The mainshaft splines may damage the sealing surface
of the lip seal if the protector sleeve is not used.
Failure to apply silicone sealer to the bolts and bolt
3.
Place the seal protector sleeve (from the MAIN DRIVE
holes on the inboard side of the primary chaincase may
GEAR SEAL INSTALLER, HD-41405) over the main-
result in oil leakage after assembly.
shaft splines. Lightly lubricate the sleeve with clean
2. On the crankcase/transmission side of the primary
engine oil.
chaincase, apply RTV silicone sealer to the following
4.
Place the primary chaincase into position against the
areas:
crankcase and transmission housings. Remove the seal
● Around the two rear primary chaincase to crank-
protector sleeve from the mainshaft.
case bolt holes. See B in left frame of Figure 6-38.
5.
See A in left frame of Figure 6-38. Start two forward
● Around the three primary chaincase to transmission
bolts (1-3/4 inches with flat washers) to fasten outside
bolt holes. See right frame of Figure 6-38.
edge of primary chaincase to front of crankcase.
2004 Touring: Drive
6-27
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
6
1
7946
Figure 6-38. Primary Chaincase Screw Size and Torque Sequence
See B in left frame of Figure 6-38. From within the pri-
8. Install alternator rotor spacer on engine sprocket shaft, if
mary chaincase, start two forward bolts (1-3/4 inches
present. See Figure 6-29.
with lockplates) to fasten primary chaincase to rear of
crankcase.
NOTE
The alternator rotor spacer is only present on those vehicles
See right frame of Figure 6-38. From within the primary
with the 38 amp low output rotor.
chaincase, start three rearward bolts (3 inches with lock-
plates) to fasten primary chaincase to front and rear of
9. Install the clutch, primary chain, compensating sprocket
transmission.
and shaft extension as a single assembly. See Figure 6-
31. Start clutch assembly on the mainshaft, while plac-
Tighten the seven bolts to 18-21 ft-lbs (24-28 Nm) in the
ing the shaft extension on the engine sprocket shaft. The
numerical sequence shown in Figure 6-38.
clutch hub and shaft extension are splined, so a slight
rotation of the chain drive will aid in lining up the splines.
Bend one tab on each lockplate against the flat of the
bolt head to secure.
10. Place sliding cam over shaft extension. Slide sprocket
cover over sliding cam. See Figure 6-29.
6.
On right side of motorcycle, install the front starter
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 13-20 ft-lbs (18-27 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 6-39.
6-28
2004 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 6-40.
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,
rotation of the primary drive is stopped.
plate in position. Verify that the retaining ring is com-
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 6-41.
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 (9-12 Nm) in the numer-
ical sequence shown in Figure 6-42.
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-
pensating sprocket nut or clutch
sary. Install drain plug back into primary chaincase cover
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 6-39. 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 6-40. Place Primary Drive Locking Tool
Figure 6-41. Place Primary Drive Locking Tool
and Torque Compensating Sprocket Nut
and Torque Clutch Hub Mainshaft Nut
2004 Touring: Drive
6-29
HOME
S = Short Screw, 1-1/4 In.
f1210x6x
CAUTION
L = Long Screw, 1-1/2 In.
S
Do not overfill the primary chaincase with lubricant.
Overfilling may cause rough clutch engagement, incom-
L
8
L
plete disengagement, clutch drag and/or difficulty in
2
finding neutral at engine idle.
S
10
S
4
25. Remove quad ring from groove in primary chaincase
6
cover. Wipe all lubricant from the quad ring and inspect
for cuts, tears or signs of deterioration. Replace as nec-
essary.
Clutch
Inspection
Primary
Cover
26. Swab all lubricant from the quad ring groove. Install
Chain
quad ring in primary chaincase cover with the nubs con-
Inspection
Cover
tacting the ring groove walls.
NOTE
9
If lubricant is not thoroughly removed from both the quad ring
5
L
Drain
7
and groove, compression of the ring during installation of the
3
1
Plug
S
clutch inspection cover can cause lubricant to be squeezed
L
S
to the outboard side of the ring groove, resulting in some
L
temporary weepage around the inspection cover.
Figure 6-42. Primary Chaincase Cover Torque Sequence
27. Using a T27 TORX drive head, install five screws (with
and Screw Size
captive washers) to secure clutch inspection cover to the
primary chaincase cover. Alternately tighten screws to
84-108 in-lbs (10-12 Nm) in the pattern shown in Figure
Primary
6-44.
Chaincase Cover
28. If installing toe and heel shifter levers, perform steps
28(a) thru
28(d). If just installing front inboard shifter
lever, perform steps 28(c) and 28(d).
a. Install rubber spacer onto end of shifter shaft.
f1210x6x
Lubricant
1
4
3
f1508b6x
2
5
Figure 6-43. Fill Primary Chaincase With Lubricant
24. Pour 32 ounces (946 ml) of Harley-Davidson PRIMARY
CHAINCASE LUBRICANT through the clutch inspection
cover opening, Part No. 99887-84 (quart) or Part No.
99886-84 (gallon). See Figure 6-43.
Figure 6-44. Clutch Inspection Cover Torque Sequence
6-30
2004 Touring: Drive
HOME
b. Set the shifter levers down, so that the Harley-
31. Install left side footboard and bracket assembly as fol-
Davidson script on the rubber peg is topside. Now
lows:
look at the socket head screw hole. If the hole is
a. Insert socket screw
(with lockwasher and flat
countersunk at the bottom, then it is the inboard
washer) through frame weldment into front foot-
shifter lever (toe). If the hole is countersunk at the
board forward bracket. For best results, approach
top, it is the outboard shifter lever (heel).
from opposite side of motorcycle using a 3/8 inch
c. Install lever(s) onto splined shaft taking note to align
ball allen with extension.
marks placed on splines during disassembly.
b. At front footboard rear bracket, slide upper hex bolt
through frame weldment, jiffy stand bracket and
d. Install socket head screw(s) to fasten lever(s) to
footboard bracket thru hole. Install lockwasher and
shaft. Tighten
1/4 inch screws to
90-110 in-lbs
locknut. Slide lower hex bolt through frame weld-
(10.2-12.4 Nm) or 5/16 inch screws to 18-22 ft-lbs
ment and jiffy stand bracket into threaded hole of
(24-30 Nm).
footboard bracket.
c. Tighten front bracket socket screw to 30-35 ft-lbs
29. Install flat washer, lockwasher and locknut to fasten
(41-48 Nm).
shifter rod to front inboard shifter lever.
d. Alternately tighten rear bracket hex bolts to 15-20 ft-
30. Install socket screw with lockwasher to fasten passenger
lbs (20-27 Nm).
footboard to rear swingarm bracket. Tighten screw to 15-
18 ft-lbs (20-24 Nm). Repeat step on opposite side of
32. Insert bolt through battery negative cable (black) into
motorcycle.
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
33. Install seat. See Section 2.24 SEAT, INSTALLATION.
2004 Touring: Drive
6-31
HOME
NOTES
6-32
2004 Touring: Drive
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
2004 Touring: Transmission
7-1
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