Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual — page 11
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200
CHAPTER FIVE
1
PRIMARY CHAINCASE
1. Oil seal
2. Chaincase inner
housing
3. Snap ring
4. O-ring
5. Pin
6. Gasket
7. Bushing
8. Locking tab
9. Bolt
10. Washer
11. Chaincase cover
12. Clutch cover
13. Drain plug
14. Gasket
15. Inspection cover
16. Bearing
2
3
b. Remove the clamping bolt (B, Figure 3) and
remove the outer shift lever.
4
c. Remove the screws and the inspection cover
and gasket
(Figure
4) from the primary
chaincase cover.
4B. On FXDWG models, remove the primary chain
inspection cover and gasket.
5. Remove the bolts and washers securing the
chaincase outer cover (Figure 5) and remove the
chaincase outer cover. Note the location of the two
different length bolts.
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CLUTCH AND PRIMARY DRIVE
201
5
9
5
6. Remove the two round gaskets (Figure 6) in-
6
stalled between the chaincase outer cover and
chaincase inner housing. The gaskets may stick to
either part.
7. Remove the chaincase outer cover gasket.
8. Remove the dowel pins, if necessary.
Inspection
1. Remove all gasket residue from the chaincase
outer cover (Figure 7) and chaincase inner housing
gasket surfaces.
2. Clean the primary cover in solvent and dry with
compressed air.
7
3. Inspect the chaincase outer primary cover for
cracks or damage.
4. Inspect the starter jackshaft bushing (Figure 8)
for excessive wear or damage. To replace the bush-
ing, perform the following:
a. Remove the bushing with a blind bearing re-
moval tool.
b. Clean the bushing bore in the housing.
c. Press in the new bushing until its outer sur-
face is flush with the edge of the bushing
bore.
Installation
8
1. Install two new round gaskets (Figure 6) on the
chaincase outer cover studs.
2. If removed, install the dowel pins (A, Figure 9)
onto the chaincase inner housing.
CAUTION
Harley-Davidson specifies that a new
Print-O-Seal gasket must be installed
every time the chaincase outer cover
is removed.
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202
CHAPTER FIVE
10
11
12
CLUTCH ASSEMBLY
1.
Snap ring
2.
Clutch shell and
sprocket
3.
Bearing
4.
Snap ring
5.
Clutch hub
6.
Clutch nut
7.
Diaphragm spring
seat
8.
Diaphragm spring
9.
Friction disc B
10.
Clutch plates
11.
Friction disc A
12.
Pressure plate
13.
Diaphragm spring
14.
Diaphragm spring
retainer
15.
Bolt
16.
Release plate
17.
Snap ring
18.
Snap ring
19.
Thrust washer
20.
Radial bearing
21.
Oil slinger
22.
Pushrod (right side)
23.
Pushrod (right side
24.
Pushrod (left side)
25.
Locknut
3. Install a new gasket (B, Figure 9) over the locat-
very large. The gasket may shift prior
ing pins and seat it against the gasket surface of the
to installing the cover bolts, so make
chaincase inner housing.
sure the gasket is positioned correctly
while installing the cover bolts in Step
4. Slide the primary cover (Figure 5) over the lo-
5.
cating dowels and seat it flush against the gaskets.
NOTE
5. Install the primary cover bolts and washers (Fig-
The gasket sealing surface is very thin
ure 10) into the correct locations noted during re-
and the overall size of the gasket is
moval. Tighten the primary cover bolts to the
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CLUTCH AND PRIMARY DRIVE
203
c. Install the clamping bolt (B, Figure 3) and
13
tighten securely.
6B. On FXDWG models, install a new gasket and
the inspection cover onto the primary chaincase
cover. Install the screws and tighten to the specifica-
tion in Table 2.
7. Install the left side footpeg assembly (Figure 2)
and tighten the bolts securely.
8. Refill the primary chaincase with the type and
quantity of oil specified under Primary Chain Lu-
brication in Chapter Three.
9. Connect the negative battery cable as described
5
in Chapter Eight.
14
CLUTCH PLATES AND
FRICTION DISCS
This section describes removal, inspection and
installation of the clutch plates. If the clutch re-
quires additional service, refer to Clutch Shell in
this chapter.
Refer to Figure 12.
Removal
NOTE
15
On models so equipped, always dis-
arm the optional TSSM security sys-
tem prior to disconnecting the battery
or the siren will sound.
1. Disconnect the battery negative lead as de-
scribed in Chapter Eight.
2. Remove the clutch mechanism inspection cover
and O-ring (Figure 13).
3. At the clutch mechanism, loosen the clutch ad-
justing screw locknut (A, Figure 14) and turn the
adjusting screw (B) counterclockwise to allow slack
specification in Table
2. Check that the gasket seats
against the diaphragm spring.
flush around the cover.
4. Remove the primary chaincase outer cover as
described in this chapter.
6A. On all models except FXDWG, perform the fol-
5. Loosen the bolts securing the diaphragm spring
lowing:
retainer (A, Figure 15) in a crisscross pattern. Re-
a. Install a new gasket (Figure 11) and the in-
move the bolts, retainer and diaphragm spring (B,
spection cover (Figure 4) onto the primary
Figure 15).
chaincase cover. Install the screws and
6. Remove the pressure plate (Figure 16).
tighten to the specification in Table 2.
7. Remove the clutch plates and friction discs from
b. Align the mark made in Step 4 Removal and
the clutch shell. After the first six clutch plates and
install the outer shift lever (A, Figure 3) onto
friction discs are removed, carefully remove the re-
inner shift lever shaft.
maining ones with a pick tool.
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204
CHAPTER FIVE
16
17
8. Remove the damper spring and damper spring
seat from the clutch shell. Keep all parts in order as
18
shown in Figure 17.
Inspection
When measuring the clutch components, com-
pare the actual measurements to the specifications
in Table 1. Replace parts that are out of specifica-
tion or show damage as described in this section.
1. Clean all parts in solvent and thoroughly dry
with compressed air.
2. Inspect the friction discs as follows:
19
NOTE
If any friction disc is damaged or out
of specification as described in the
following steps, replace all of the fric-
tion discs as a set. Never replace only
one or two discs.
a. The friction material used on the friction
discs (Figure 18) is bonded onto an alumi-
num plate for warp resistance and durability.
Inspect the friction material for excessive or
uneven wear, cracks and other damage.
20
Check the disc tangs for surface damage. The
sides of the disc tangs must be smooth where
they contact the clutch shell fingers; other-
wise, the discs cannot engage and disengage
correctly.
NOTE
If the disc tangs are damaged, inspect
the clutch shell fingers carefully as
described later in this section.
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CLUTCH AND PRIMARY DRIVE
205
21
25
5
b. Measure the thickness of each friction disc
22
with a vernier caliper (Figure 19). Measure at
several places around the disc.
3.
Inspect the clutch plates (Figure 20) as follows:
a. Inspect the clutch plates for cracks, damage
or color change. Overheated clutch plates will
have a blue discoloration.
b. Check the clutch plates for an oil glaze
buildup. Remove by lightly sanding both
sides of each plate with 400 grit sandpaper
placed on a surface plate or piece of glass.
c. Place each clutch plate on a flat surface and
check for warp with a feeler gauge (Figure
21).
23
d. The clutch plate inner teeth mesh with the
clutch hub splines. Check the clutch plate
teeth for any roughness or damage. The teeth
contact surfaces must be smooth; otherwise,
the plates cannot engage and disengage cor-
rectly.
NOTE
If the clutch plate teeth are damaged,
inspect the clutch hub splines care-
fully as described later in this section.
4.
Inspect the diaphragm spring (Figure 22) for
cracks or damage.
24
5. Inspect the diaphragm spring retainer for cracks
or damage. Also check for bent or damaged tabs
(Figure 23).
6. Inspect the pressure plate contact surface (Fig-
ure 24) for cracks or other damage.
7. If necessary, disassemble the pressure plate as
follows:
a. Remove the snap ring and remove the release
plate, left side pushrod and locknut (Figure
25) from the pressure plate.
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206
CHAPTER FIVE
26
28
27
29
b. Inspect the release plate, left side pushrod and
locknut for wear or damage.
30
c. Inspect its snap ring groove for damage.
d. Position the release plate with the OUT mark
facing out (Figure 26) and install the assem-
bly into the pressure plate.
e. Install the snap ring and make sure it is cor-
rectly seated in the pressure plate groove.
Installation
NOTE
The clutch assembly (Figure 17) has
nine friction plates, eight steel plates,
31
one damper spring and one damper
spring seat. Make sure each is in-
stalled. If installing an aftermarket
clutch plate assembly, follow the man-
ufacturer’s instructions for plate
quantity, alignment and installation
sequence.
1. Soak the clutch friction disc and clutch plates in
new primary drive oil for approximately 5 minutes
before installing them.
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CLUTCH AND PRIMARY DRIVE
207
32
36
5
NOTE
33
There are two different types of clutch
friction discs (Figure 27). The wider
friction disc A is the normal width
disc, while the narrow width friction
disc B is installed first, as it works in
conjunction with the damper spring
and damper spring seat.
2. Install the clutch friction disc B (Figure 28) onto
the clutch shell and clutch hub. Push it on all the
way until it bottoms within the clutch hub.
3. Install the damper spring seat (Figure 29) onto
the clutch hub and push it in until it seats within the
clutch friction disc B.
34
4. Position the damper spring with the dome side
facing out (Figure 30) and install it onto the clutch
hub against the damper spring seat (Figure 31).
5. Install a clutch plate (Figure 32), then a friction
disc A (Figure 33). Continue to alternately install
the clutch plates and friction discs. The last part in-
stalled is a friction disc A (Figure 34).
6. Make sure the oil slinger assembly (Figure 35)
is in place in the pressure plate. Install the pressure
plate onto the clutch hub (Figure 16).
7. Position the diaphragm spring with the dished
side facing out (Figure 36) and install it onto the
35
pressure plate (Figure 37). Hold the pressure plate
in place.
8. Position the diaphragm spring retainer with the
finger side (Figure 38) facing in toward the dia-
phragm spring (B, Figure 15). Install the dia-
phragm spring retainer (A, Figure 15) and bolts.
9. Tighten the bolts in a crisscross pattern to the
specification in Table 2.
10. Install the primary chaincase outer cover as de-
scribed in this chapter.
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208
CHAPTER FIVE
37
38
39
COMPENSATING SPROCKET (1999-2000)
1. Bolt
2. Anchor plate
3. Screw
4. Chain tensioner
5. Plate
6. Washer
7. Nut
8. Tensioner pad
9. Washer
10. Lockwasher
11. Bolt
12. Primary chain
13. Spacer
14. Shaft extension
15. Compensating sprocket
16. Sliding cam
17. Cover assembly with
springs*
18. Nut*
*Spacer between No. 17 and
No. 18 for 1999 models not
shown
11. Install the clutch mechanism inspection cover
Refer to Figure 12 (clutch assembly), Figure 39
and O-ring (Figure 13).
(1999-2000 models) and Figure 40 (2001 models).
12. Connect the negative battery cable as described
in Chapter Eight.
NOTE
On models so equipped, always dis-
arm the optional TSSM security sys-
CLUTCH SHELL, COMPENSATING
tem prior to disconnecting the battery
SPROCKET AND PRIMARY
or the siren will sound.
DRIVE CHAIN
Removal
1. Disconnect the negative battery cable from the
battery as described in Chapter Eight
This procedure describes clutch shell, primary
chain and engine sprocket removal. These compo-
2. Remove the primary chaincase outer cover as
nents must be removed as an assembly.
described in this chapter.
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CLUTCH AND PRIMARY DRIVE
209
40
COMPENSATING SPROCKET (2001)
1. Bolt
2. Anchor plate
3. Screw
4. Washer
5. Nut
5
6. Primary chain
7. Chain tensioner
8. Pad
9. Snap ring
10. Spacer
11. Shaft extension
12. Compensating sprocket
13. Sliding cam
14. Cover assembly with
springs*
15. Nut*
*Spacer between No. 14 and
No. 15 not shown
3. Remove the diaphragm spring, pressure plate,
41
clutch plates and friction discs as described in this
chapter.
CAUTION
Do not clamp the special tool too tight
as it may damage the grooves in the
clutch hub.
4A. If the special tool is available, such as the
Grabbit (Figure 41), attach it to the clutch hub to
keep it from turning.
4B. If the special tool is not available, shift the
transmission into fifth gear. Have an assistant apply
42
the rear brake.
CAUTION
The clutch nut has left-hand threads.
Turn the clutch nut clockwise to
loosen it.
5. Loosen the clutch nut (Figure 42) with an im-
pact wrench. Remove the clutch nut.
6. Loosen the compensating sprocket nut (Figure
43) with an impact wrench.
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210
CHAPTER FIVE
43
45
44
46
7. Remove the compensating sprocket nut (Figure
43), washer (1999 models), cover (Figure 44) and
47
sliding cam (Figure 45).
8A. On 1999-2000 models, perform the follow-
ing:
a. Remove the primary chain shoe adjuster
locknut (Figure 46).
b. Remove the compensating sprocket, pri-
mary chain, chain adjuster and clutch as-
sembly (Figure 47) at the same time. See
Figure 48.
8B. On 2001 models, perform the following:
a. Loosen the primary chain shoe adjuster
locknut (A, Figure 49) and push the tensioner
48
assembly down to relieve tension on the pri-
mary chain.
b. Remove the compensating sprocket, primary
chain and clutch assembly (B, Figure 49) at
the same time. See Figure 50.
9. Remove the shaft extension (Figure 51) and the
spacer (Figure 52).
10. Inspect the various components as described in
this chapter.
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CLUTCH AND PRIMARY DRIVE
211
49
53
5
Installation
50
1. Remove all threadlocking compound residue
from the crankshaft and mainshaft threads and from
the compensating sprocket nut and the clutch nut.
2. Remove all gasket residue from the inner pri-
mary housing gasket surfaces.
3. Install the spacer (Figure 52) and the shaft ex-
tension (Figure 51) onto the crankshaft.
4A. On 1999-2000 models, perform the following:
a. Assemble the compensating sprocket, pri-
mary chain, chain adjuster and clutch as
shown in Figure 48.
b. Install the compensating sprocket, primary
51
chain, chain adjuster and clutch as shown in
Figure
47. Insert the chain adjuster bolt
through the chain adjuster hole as shown in
Figure 53.
c. Install the primary chain shoe adjuster
locknut (Figure 46) and tighten finger-tight
at this time.
4B. On 2001 models, perform the following:
a. Assemble the compensating sprocket, pri-
mary chain and clutch as shown in Figure
50.
b. Install the compensating sprocket, primary
chain and clutch as shown in B, Figure 49.
52
5. Install the compensating sprocket (Figure 45)
and the cover (Figure 44).
6. On 1999 models, install the washer.
7. Install the same tool setup (A, Figure 54) used
during removal or shift the transmission into fifth
gear to prevent the compensating sprocket and
clutch shell from rotating during the following
steps.
8. Apply two drops of ThreeBond TB1360 or an
equivalent to the compensating sprocket nut
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212
CHAPTER FIVE
threads. Install the nut (Figure 43) and tighten
(Figure 55) to the specification in Table 2.
54
NOTE
The clutch nut has left-hand threads.
Turn the nut counterclockwise to
tighten it.
9. Apply two drops of ThreeBond TB1360 or an
equivalent to the clutch nut threads. Install the nut
(Figure 42) and tighten (B, Figure 54) to the speci-
fication in Table 2.
10. If used, remove the special tool from the clutch
shell.
11. Adjust the primary chain as described in Chap-
55
ter Three.
12. Install the clutch plates and friction discs, pres-
sure plate and diaphragm spring as described in this
chapter.
13. Install the primary chaincase outer cover as de-
scribed in this chapter.
14. Adjust the clutch as described in Chapter
Three.
15. Connect the negative battery cable to the bat-
tery as described in Chapter Eight.
CLUTCH SHELL, CLUTCH
56
HUB AND SPROCKET
Inspection
The clutch shell is a subassembly consisting of
the clutch shell, the clutch hub, the bearing and two
snap rings.
1. Remove the clutch shell as described in this
chapter.
2. Hold the clutch shell and rotate the clutch hub by
hand. The bearing is damaged if the clutch hub
binds or turns roughly.
3. Check the sprocket
(A, Figure 56) and the
57
starter ring gear (B, Figure 56) on the clutch shell
for cracks, deep scoring, excessive wear or heat dis-
coloration.
4. If the sprocket or the ring gear are worn or dam-
aged, replace the clutch shell. If the primary chain
sprocket is worn, also check the primary chain and
the compensating sprocket as described in this
chapter.
5. Inspect the clutch hub for the following condi-
tions:
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CLUTCH AND PRIMARY DRIVE
213
a. The clutch plate teeth slide in the clutch hub
58
splines (A, Figure 57). Inspect the splines
for rough spots, grooves or other damage.
Repair minor damage with a file or oil stone.
If the damage is severe, replace the clutch
hub.
b. Inspect the clutch hub inner splines (Figure
58) for galling, severe wear or other dam-
age. Repair minor damage with a fine cut
file. If damage is severe, replace the clutch
hub.
c. Inspect the bolt towers and threads (B, Figure
5
57) for thread damage or cracks at the base of
the tower. Repair thread damage with correct
59
size metric tap. If the tower(s) is cracked or
damaged, replace the clutch hub.
6. Check the clutch shell. The friction disc tangs
slide in the clutch housing grooves (C, Figure 57).
Inspect the grooves for cracks or galling. Repair mi-
nor damage with a file. If the damage is severe, re-
place the clutch housing.
7. If the clutch hub, the clutch shell or bearings are
damaged, replace them as described in the follow-
ing procedure.
Disassembly/Assembly
60
Do not separate the clutch hub and shell unless
the bearing or either part is going to be replaced. If
the two parts are separated the bearing will be dam-
aged.
Removal and installation of the bearing re-
quires the use of a hydraulic press.
Refer to Figure 12.
1. Remove the clutch as described in this chapter.
Remove the clutch shell assembly from the primary
drive chain.
2. Remove the snap ring (Figure 59) from the
61
clutch hub groove.
3. Position the clutch hub and shell with the pri-
mary chain sprocket side facing up.
4. Support the clutch hub and clutch shell in a press
(Figure 60).
5. Place a suitable size arbor in the clutch hub sur-
face and press the clutch hub (A, Figure 61) out of
the bearing.
6. Remove the clutch shell from the press (B, Fig-
ure 61).
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214
CHAPTER FIVE
62
63
Flat side against bearing
7. On the inner surface of the clutch shell, remove
the bearing retaining snap ring (Figure 62) from the
64
groove in the middle of the clutch shell.
CAUTION
Press the bearing out from the pri-
Clutch hub
mary chain sprocket side of the clutch
shell. The bearing bore has a shoulder
Clutch
Press
shell
on the primary chain side.
8. Support the clutch shell in the press with the pri-
mary chain sprocket side facing up.
9. Place a suitable size arbor on the bearing inner
Bearing
race and press the bearing out of the clutch shell
(Figure 63).
10. Thoroughly clean the clutch hub and shell in
solvent and dry with compressed air.
11. Inspect the bearing bore in the clutch shell for
Sleeve
damage or burrs. Clean off any burrs that would in-
terfere with new bearing installation.
12. Support the clutch shell in the press with the
primary chain sprocket side facing down.
shell until it bottoms on the lower shoulder. Press
13. Apply chaincase lubricant to the clutch shell
only on the outer bearing race. Applying force to the
bearing receptacle and the outer surface of the
bearing’s inner race will damage the bearing. Refer
bearing.
to Basic Service Methods in Chapter One for addi-
14. Align the bearing with the clutch shell receptacle.
tional information.
15. Place a suitable size arbor on the bearing outer
16. Position the new snap ring with the flat side
race and slowly press the bearing into the clutch
against the bearing and install the snap ring into the
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CLUTCH AND PRIMARY DRIVE
215
65
67
5
roughly, the bearing was installed incorrectly. Re-
66
peat this procedure until this problem is corrected.
PRIMARY CHAIN AND
GUIDE INSPECTION
1. Remove the primary chain as described under
the Clutch Shell, Compensating Sprocket and Pri-
mary Drive Chain in this chapter.
2. Clean the primary chain in solvent and dry thor-
oughly.
3. Inspect the primary chain (Figure 66) for exces-
clutch shell groove (Figure 62). Make sure the snap
sive wear, cracks or other damage. If the chain is
ring is seated correctly in the clutch shell groove.
worn or damaged, check both sprockets for wear
17. Press the clutch hub into the clutch shell as fol-
and damage.
lows:
NOTE
If the primary chain is near the end of
CAUTION
its adjustment level or if no more ad-
Failure to support the inner bearing
justment is available, and the adjust-
race properly will cause bearing and
ing guide (Figure 67) is not worn or
clutch shell damage.
damaged, the primary chain is exces-
sively worn. Service specifications for
a. Place the clutch shell in a press. Support the
chain wear are not available.
inner bearing race with a sleeve as shown in
Figure 64.
4. Inspect the adjusting guide
(Figure
67) for
b. Align the clutch hub with the bearing and
cracks, severe wear or other damage. Replace the
slowly press the clutch hub into the bearing
adjusting shoe if necessary.
until the clutch hub shoulder seats against the
bearing inner race.
PRIMARY CHAIN ALIGNMENT
c. Install a new snap ring (Figure 59) into the
clutch hub. Make sure the snap ring is seated
A spacer, installed behind the compensating
correctly in the clutch hub groove.
sprocket, aligns the compensating and clutch
18. After completing assembly, hold the clutch
sprockets. Install the original spacer when reinstall-
shell (A, Figure 65) and rotate the clutch hub (B) by
ing the compensating sprocket, primary chain and
hand. The shell must turn smoothly with no rough-
clutch assembly. However, if the primary chain is
ness or binding. If the clutch shell binds or turns
showing wear on one side, or if new components
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216
CHAPTER FIVE
68
70
69
71
have been installed that could affect alignment, per-
form the following check.
72
1. Remove the outer primary cover as described in
this chapter.
2. Adjust the primary chain tension so the chain is
snug against both the compensating sprocket and
clutch shell sprocket.
3. Push the primary chain toward the engine and
transmission (at both sprockets) as far as it will go.
4. Place a straightedge on the primary chain side
plates, close to the compensating sprocket.
5. Measure the distance from the chain link side
plates to the primary chaincase housing gasket sur-
face. Record the measurement.
6. Repeat Steps 4 and 5 with the end of the straight-
73
edge as close to the clutch sprocket as possible. Re-
cord the measurement.
7. The difference between the
2 measurements
must be within 0.030 in. (0.76 mm) of each other. If
the difference exceeds this amount, replace the
spacer (Figure 52) with a suitable size spacer. Refer
to Table 3 for spacer thickness and part number.
8. To replace the spacer, perform the Clutch Shell,
Compensating Sprocket and Primary Drive Chain
in this chapter.
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CLUTCH AND PRIMARY DRIVE
217
74
PRIMARY CHAINCASE
5
1. Oil seal
9. Bolt
2. Chaincase inner housing
10. Washer
3. Snap ring
11. Chaincase cover
4. O-ring
12. Clutch cover
5. Pin
13. Drain plug
6. Gasket
14. Gasket
7. Bushing
15. Inspection cover
8. Locking tab
16. Bearing
9. Install the outer primary cover as described in
5. Check the compensating sprocket inner bushing
this chapter.
(Figure 70) for wear.
10. Check and adjust the primary chain tension as
6. Check the sliding cam inner splines (Figure 71)
described in Chapter Three.
for wear.
7. Check the shaft extension splines for wear or
COMPENSATING SPROCKET
galling.
INSPECTION
8. Check the cover (Figure 72) for damage.
9. Inspect the inner threads (Figure 73) of the nut
Refer to Figure 39 (1999-2000 models) and Fig-
for damage.
ure 40 (2001 models).
10. If any of these components were replaced,
1. Remove the compensating sprocket assembly as
check the primary chain alignment as described in
described in this chapter.
this chapter.
2. Clean all parts in solvent and dry with com-
pressed air.
3. Check the cam surfaces (Figure 68) for cracks,
PRIMARY CHAINCASE
deep scoring or wear.
INNER HOUSING
4. Check the compensating sprocket gear teeth
(Figure 69) for cracks or wear.
The primary chaincase inner housing is bolted to
the engine and transmission. It houses the primary
NOTE
drive assembly, flywheel, starter jackshaft and the
If the compensating sprocket teeth are
mainshaft oil seal and bearing assembly.
worn, check the primary chain and the
clutch shell gear teeth for wear.
Refer to Figure 74.
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218
CHAPTER FIVE
75
76
Removal
77
NOTE
On models so equipped, always dis-
arm the optional TSSM security sys-
tem prior to disconnecting the battery
or the siren will sound.
1. Disconnect the negative battery cable from the
battery as described in Chapter Eight.
2. Remove the primary chaincase outer cover as
described in this chapter.
3. Remove the compensating sprocket, primary
chain and clutch assembly as described in this chap-
78
ter.
4. Remove the starter motor as described in Chap-
ter Eight.
5. Pry the lockwasher tabs away from the inner pri-
mary housing bolts (Figure 75, typical).
6. Loosen and then remove the five bolts (Figure
76) securing the inner housing to the engine and the
transmission. Discard the lockwashers, as new ones
must be installed.
7. Remove the starter jackshaft assembly from the
inner housing.
79
8. Tap the inner primary housing loose.
9A. On all models except the FXDWG, carefully
pull the inner housing (A, Figure 77) away from the
engine and transmission. Guide the inner shift shaft
(B, Figure 77) out from the inner housing.
9B. On FXDWG models, remove the inner housing
from the engine and transmission.
10. Remove the O-ring (Figure 78) from the en-
gine crankcase shoulder.
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CLUTCH AND PRIMARY DRIVE
219
80
84
5
Inspection
81
1. Remove all gasket residue from the inner hous-
ing gasket surfaces (Figure 79).
2. Clean the inner housing in solvent and dry thor-
oughly.
3. Check the inner housing (Figure 80) for cracks
or other damage.
4. Check the starter jackshaft oil seal (Figure 81)
for excessive wear or damage. To replace the oil
seal, perform the following:
a. Note the direction the oil seal lip faces in the
housing.
b. Pack the new oil seal lips with grease.
82
Inner primary housing
c. Pry the oil seal out of the inner primary hous-
ing.
d. Carefully drive the new oil seal into the hous-
ing until it seats against the housing shoulder
(Figure 82).
5. Inspect the starter jackshaft bushing (Figure 83)
Jackshaft oil
seal
for excessive wear, cracks or other damage. To re-
place the bushing, perform the following:
Shoulder
a. Remove the bushing with a blind bearing re-
moval tool.
b. Clean the bushing bore in the housing.
c. Press in the new bushing until its outer sur-
83
face is flush with the edge of the bushing
bore.
6. Turn the inner bearing race (Figure 84) by hand.
Replace the bearing as follows:
a. Remove the oil seal (Figure 85) as described
in Step 7.
b. Remove the inner and outer bearing snap
rings (Figure 86).
c. Support the inner primary housing and press
the bearing out.
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