Harley Davidson 2018 softail models. Service manual — page 18
WARNING
Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over
bending can damage belt resulting in premature failure, which could cause loss of control and death or serious injury.
(00339a)
1.
See Figure 1. Install drive belt (3) on final drive sprocket.
2.
Install pivot shaft.
a. Position round spacer (2) between drive belt (3),
frame and rear fork.
b. Slide pivot shaft through round spacer and left side of
frame.
c. Install pivot shaft nut (1). Tighten.
Torque: 34-41 N·m (25-30 ft-lbs) Rear fork pivot
shaft nut, first torque
d. Back off pivot shaft nut.
Angle: 90°
e. Tighten pivot shaft nut.
Torque: 0.1-5.4 N·m (1-48 in-lbs) Rear fork pivot
shaft nut, second torque
3.
NOTE
Verify round spacer (2) does not have lateral play.
Install slot spacer.
a. Place slot spacer (4) in the center of the drive belt and
between frame and rear fork.
b. Install slot spacer screws (5). Tighten.
Torque: 68-75 N·m (50-55 ft-lbs) Drive belt slot
spacer screw, first torque
c. Loosen slot spacer screws.
Angle: 90°
d. Tighten slot spacer screws.
Torque: 88-95 N·m (65-70 ft-lbs) Drive belt slot
spacer screw, final torque
4.
Place drive belt on sprocket and install rear wheel. See
Prepare.
NOTE
Adjust the belt tension after the drive belt slot spacer
screws have been torqued to final specifications and
before the pivot shaft nut has been torqued to final
specifications.
5.
Tighten pivot shaft nut (1).
a. Tighten pivot shaft nut.
Torque: 209-230 N·m (154-170 ft-lbs) Rear fork pivot
shaft nut, third torque
b. Loosen pivot shaft nut.
Angle: 90°
c. Tighten pivot shaft nut.
Torque: 209-230 N·m (154-170 ft-lbs) Rear fork pivot
shaft nut, final torque
NOTE
After final torque of pivot shaft nut there will be a
slight gap between the right side bearing and
rear fork.
6.
NOTE
Verify round spacer (2) does not have lateral play.
See Rear Fork Assembly. Tighten pivot shaft pinch bolt.
Torque: 24-27 N·m (18-20 ft-lbs) Rear fork pivot shaft
pinch bolt
1
Pivot shaft nut
2
Round spacer
3
Drive belt
4
Slot spacer
5
Slot spacer screw (2)
Figure 1. Drive Belt
1. Install primary chaincase housing. See Prepare.
2. Install the primary chain, clutch, compensating sprocket and chain tensioner. See Prepare.
3. Install starter. See Prepare.
4. Install primary chaincase cover and new gasket. See Prepare.
5. Fill primary chaincase oil. See Change Primary Chaincase Lubricant.
6. Mid-mount controls: Install foot shift lever. See Shifter Rod.
7. Install rider left footboard and bracket, if removed. See Prepare.
8. Install mufflers and exhaust bracket. See Prepare.
9. Install saddlebags if equipped. See Remove and Install: Standard.
10. Connect negative battery cable. See Main Fuse.
Replace
Front Foot Control Models
1. See Figure 1. Discard nut (2) and remove screw (6)
from front shifter rod lever (1).
2. Remove screw (5) from rear shifter rod lever (4).
3. Remove shifter rod (3)
4. Install shifter rod.
a. Install shifter rod to each shifter rod lever.
b. Install screw (5). Tighten.
Torque: 13.6-19 N·m (120-168 in-lbs) Shifter
rod to rear shifter rod lever, front foot control
c. Install screw (6) and new nut. Tighten. Torque:
13.6-19 N·m (120-168 in-lbs) Shifter rod to
front shifter rod lever, front foot control
Mid-Mount Foot Control Models
1. See Figure 2. Remove screws (4).
2. Remove shifter rod (3).
3. Install shifter rod.
a. Install shifter rod to each shifter rod lever.
b. Install screws. Tighten.
Torque: 13.6-19 N·m (120-168 in-lbs) Shifter
rod to shifter rod lever, mid-mount control
Adjust
NOTE
The shifter rod should not require adjustment under normal circumstances. However, if full gear engagement
or full lever travel is not achieved, adjust the shifter rod.
Do not allow shift lever to contact footboard or support bracket when shifting. This prevents proper gear
engagement. Contact may also damage the transmission.
1. See Figure 1 or Figure 2. Disconnect forward end of
shifter rod from forward shifter rod lever.
2. Loosen jamnuts. Adjust rod (3) as necessary.
3. Secure shifter rod to front shifter rod lever. Tighten..
Torque: 13.6-19 N·m (120-168 in-lbs) Shifter rod to
shifter rod lever
4. Tighten jamnuts.
Torque: 9.5-14.9 N·m (84-132 in-lbs) Shifter rod
jamnut
1
Shifter rod lever, front
2
Nut
3
Shifter rod
4
Shifter rod lever, rear
5
Screw
6
Screw
7
Pinch screw
8
Nut
Figure 1. Shift Linkage: Forward Foot Control Models
1
Shifter rod lever, front
2
Shifter rod lever, rear
3
Shifter rod
4
Screw (2)
5
Pinch screw
6
Washer
7
Foot shift lever
8
Spacer
9
Nut
10
Shaft
11
Pinch screw
Figure 2. Shift Linkage: Mid-Mount Foot Control Models
Removal
1. See Shift Linkage: Forward Foot Control Models or Shift Linkage: Mid-Mount Foot Control Models. Mark
position of lever in relation to shaft.
2. Mid-Mount Foot Control Models: Remove nut (9). Front-Mount Foot Control Models: Remove nut (8).
3. Remove pinch screw securing foot shift lever.
4. Remove lever from shaft.
5. Mid-Mount Foot Control Models: Remove spacer (8).
Repair
1. Remove screw securing rubber peg to lever. Separate
screw from peg.
2. Assemble peg to lever with screw. Tighten.
Torque: 10.9-16.3 N·m (96-144 in-lbs) Shifter peg
screw
Installation
1. Mid-Mount Foot Control Models: Install spacer (8).
NOTE
Foot shift lever peg height is a customer preference.
During installation, check operation of shift lever.
To achieve proper gear engagement and to avoid
damage to transmission, the peg must not contact
the footboard or supports when shifting.
2. Install foot shift lever.
a. Align to marks made during removal.
b. Press foot shift lever onto shaft.
c. Install pinch screw and nut.
d. Tighten.
Torque: 32.5-38 N·m (24-28 ft-lbs) Mid-Mount Foot
shift lever pinch screw
Torque: 12.2-16.3 N·m (108-144 in-lbs) Front-
Mount Foot shift lever pinch screw
3. Verify shift lever operation.
Removal
1. See Shift Linkage: Forward Foot Control Models or Shift Linkage: Mid-Mount Foot Control Models.
Remove screw to free linkage from front shifter rod lever (1).
2. Mark position of foot shift lever in relation to shaft.
3. Front-Mount Foot Control Models:
a. See Shift Linkage: Forward Foot Control Models. Remove pinch screw (7) and nut (8).
b. Remove foot shift lever assembly.
c. Remove shifter rod lever and shaft.
4. Mid-Mount Foot Control Models:
a. See Shift Linkage: Mid-Mount Foot Control Models. Remove pinch screw from front shifter rod lever
(1).
b. Pull foot shifter rod lever (1) and shaft outward until shifter rod lever is free.
c. Remove shifter rod lever (7).
Installation
1. Front-Mount Foot Control Models:
a. See Shift Linkage: Forward Foot Control Models.
Install shifter rod lever (1) and shaft.
b. Install foot shift lever, aligning to marks made during
removal.
c. Install pinch screw (7). Tighten.
Torque: 12.2-16.3 N·m (9-12 ft-lbs) Foot shift lever
pinch screw, front-mount
d. Connect shifter rod. Tighten.
Torque: 13.6-19 N·m (120-168 in-lbs) Shifter rod to
shifter rod lever, front-mount
2. Mid-Mount Foot Control Models:
a. See Shift Linkage: Mid-Mount Foot Control
Models. Hold shifter rod lever (1) in place.
b. Push foot shift lever and rod into shifter rod lever
aligning splines as they mate.
c. Install pinch screw. Tighten.
Torque: 24.4-29.8 N·m (18-22 ft-lbs) Shifter rod
lever pinch screw, mid-mount
3. Secure linkage to shifter rod lever (1). Tighten. Torque:
13.6-19 N·m (120-168 in-lbs) Shifter rod to shifter rod
lever, mid-mount
4. Verify shifter rod operation.
1. Remove main fuse. See Main Fuse
2. Remove exhaust system if needed. See Prepare.
3. Drain transmission. See Check Transmission Lubricant.
1.
NOTE
Actuating the clutch hand lever after removing the six
screws will help break the cover free.
See Figure 1. Remove screws.
2. Remove clutch release cover.
3. Discard gasket.
Figure 1. Clutch Release Cover Torque Sequence (Short Screws at Locations 1 and 6)
1. Verify that two dowel pins are in place on transmission
bearing housing flange.
2. Install new gasket.
3. Install clutch release cover.
4.
NOTE
See Clutch Release Cover Torque Sequence
(Short Screws at Locations 1 and 6). Clutch
release cover screws in positions (1) and (6) are
shorter than the others.
Install screws. Tighten in sequence shown.
Torque: 14.9-17.6 N·m (132-156 in-lbs) Clutch release
cover screws
5. Tighten clutch cable fitting, if removed.
Torque: 10.2-13.6 N·m (90-120 in-lbs) Clutch cable
fitting
1.
NOTE
Do not separate clutch cable halves.
Add free play to clutch cable. See Check and Adjust.
WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip
from the pliers and could be propelled with enough
force to cause serious eye injury. (00312a)
2. See Figure 1. Disconnect clutch cable.
a. Remove retaining ring (4).
b. Lift inner ramp (5) and ramp coupling (3) out of clutch
release cover.
c. Disconnect clutch cable end (2) from the ramp
coupling (3).
3. Remove coupling (3) from inner ramp.
4. See Figure 2. Remove balls (4) and outer ramp (2).
5. Remove clutch cable fitting from clutch release cover.
1
Cable fitting
2
Clutch cable end
3
Ramp coupling
4
Retaining ring
5
Inner ramp
6
Retaining ring opening
Figure 1. Clutch Cable Connection
1
Inner ramp
2
Outer ramp
3
Outer ramp tab
4
Balls (3)
5
Ramp coupling
Figure 2. Coupling and Ramp Assembly
1. See Figure 1. Wash the ball and ramp mechanism components in cleaning solvent.
2. Inspect the three balls (2) and ball socket surfaces on ramps (1, 3) for wear, pitting, surface breakdown and other
damage. Replace as necessary.
3. Check fit of the ramp coupling (4) on inner ramp (1). Replace both parts if there is excessive wear.
4. Inspect the retaining ring (6) for damage or distortion.
5. Check clutch cable end for frayed or worn ends. Replace cable if damaged or worn. Check cable fitting O-ring for
damage.
6. Check the bore in the clutch release cover (5) where the ramps (1, 3) are retained. There should be no wear that
would cause the ramps to tilt, causing improper clutch adjustment.
1
Inner ramp
2
Ball (3)
3
Outer ramp
4
Ramp coupling
5
Clutch release cover
6
Retaining ring
7
Gasket
8
Tab
Figure 1. Release Mechanism Assembly
NOTE
Replace cable fitting O-ring if damaged.
1.
See Clutch Cable Connection. Apply a drop of LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) to the clutch cable fitting (1).
2.
Install clutch cable fitting in clutch release cover. Leave
fasteners loose.
3.
See Release Mechanism Assembly. Place outer ramp
(3) with ball socket side up in clutch release cover.
Confirm tab (8) is in clutch release cover slot.
4.
Apply a multi-purpose grease to the balls and outer ramp
sockets. Place a ball in each of the outer ramp sockets.
5.
See Clutch Cable Connection. Connect clutch cable.
a. Connect cable end to ramp coupling (3).
b. Install coupling on inner ramp (5).
c. Place inner ramp and coupling in position in clutch
release cover.
WARNING
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip
from the pliers and could be propelled with enough
force to cause serious eye injury. (00312a)
6.
Install retaining ring.
a. Center opening of retaining ring above break in
ribbing at bottom of clutch release cover.
b. Install retaining ring (4).
1. Fill transmission. See Check Transmission Lubricant.
2. Adjust clutch. See Check and Adjust.
3. Install exhaust system. See Prepare.
4. Install main fuse. See Main Fuse
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove rider left footboard and bracket, if necessary. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
1. See Primary Chaincase Cover. Remove primary
chaincase cover.
a.
Remove cover screws (4, 5).
b.
Remove cover.
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1. See Figure 1. Verify that all debris is washed from the
inside ribs of the cover.
2. Verify hollow dowels (2) are installed properly.
3. Install new cover gasket (1).
4. Install cover.
a. Apply a drop of threadlocker to the threads of each
screw.
LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (BLUE) (99642-97)
b. Install cover with screws (4, 5) in positions shown.
c. See Figure 2. Tighten in sequence shown. Torque:
16.3-17.6 N·m (144-156 in-lbs) Primary cover screws
1
Gasket
2
Hollow dowel
3
Cover
4
Screws, short (9)
5
Screws, long (4)
Figure 1. Primary Chaincase Cover
Figure 2. Primary Chaincase Cover Torque Sequence
1. Fill primary chaincase with oil. See Change Primary
Chaincase Lubricant.
2. Mid-mount controls: Install foot shift lever. See Shifter
Rod.
3. Install rider footboard and bracket, if removed. See
Prepare.
4. Install negative battery cable. See Main Fuse.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove rider left footboard and bracket, if necessary. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Remove primary chaincase cover. See Prepare.
Special Tools
Description
Part Number
Qty.
PRIMARY DRIVE LOCKING TOOL
HD-47977
1
1. See Securing Chain Tensioner. Remove chain tensioner.
a. Install cable strap (2) as shown. Exposed portion of cable strap below cover indicates need for removal
before cover installation.
b. See Chain Tensioner. Remove chain tensioner fasteners (2).
c. Remove chain tensioner (1).
NOTE
Clutch hub does not need to be removed when removing compensating sprocket.
2. Mark one of the links of the primary chain for reference during installation.
3. Remove retaining ring and release plate from center of clutch assembly.
NOTE
The mainshaft nut has left-hand threads.
4. See Removing Clutch Hub Mainshaft Nut. Remove mainshaft nut.
a. Place special tool between the sprockets as shown.PRIMARY DRIVE LOCKING TOOL (Part
Number:HD-47977)
b. Wide frame only: See Engine Compensating Sprocket Assembly. Discard oil spinner (10).
c. Removing Clutch Hub Mainshaft Nut. Rotate clutch hub mainshaft nut (4) clockwise to remove.
5. See Removing Clutch Hub Mainshaft Nut. Remove compensating sprocket bolt.
a. Place the primary drive locking tool between the sprockets as shown.
b. Rotate compensating sprocket bolt (1) counterclockwise to loosen.
c. See Engine Compensating Sprocket Assembly. Remove bolt (9), retainer (8) and thrust washer (7).
6. Inspect thrust washers (7) for damage.
7. Clean sprocket retainer (8). Verify that oil holes are clear.
Special Tools
Description
Part Number
Qty.
PRIMARY DRIVE LOCKING TOOL
HD-47977
1
NOTE
The O-ring inside the shaft extension is for manufacturing assembly only and has no replacement part number.
1.
See Engine Compensating Sprocket Assembly and
Spring Washer Orientation. Install spring washers.
a. Apply a thin layer of primary chaincase oil to the inner
diameter of the compensating sprocket (6) and the
splines of shaft extension (1).
b. Install shaft extension.
c. Install large spring washers (2) and medium spring
washers (3). Outer diameter of spring washers must
contact each other.
d. Install small spring washer (4) so outer diameter
contacts sliding cam (5).
2.
Install primary chain, compensating sprocket and clutch.
3.
Lightly lubricate thrust washer (7). Install components (7,
8) and new bolt (9). Hand tighten.
NOTE
Clutch hub mainshaft nut has left-hand threads.
4.
See Installing Clutch Hub Mainshaft Nut. Install
mainshaft nut.
a. Clean and prime threads of clutch hub mainshaft nut
(2).
b. Apply two drops of LOCTITE 262 HIGH STRENGTH
THREADLOCKER AND SEALANT (red) to the
threads.
c. Install nut onto mainshaft. Hand-tighten.
5.
See Installing Engine Compensating Sprocket Bolt.
Tighten compensating sprocket bolt.
a. Place special tool between the sprockets as shown.
Special Tool: PRIMARY DRIVE LOCKING TOOL
(HD-47977)
b. Tighten compensating sprocket bolt (1).
Torque: 135.6 N·m (100 ft-lbs) Compensating
sprocket bolt, first torque
c. Loosen one-half turn.
d. Final torque.
Torque: 237.3 N·m (175 ft-lbs) Compensating
sprocket bolt, final torque
6.
Wide frame only: See Engine Compensating Sprocket
Assembly. Install new oil spinner (10).
7.
See Installing Clutch Hub Mainshaft Nut. Tighten clutch
hub mainshaft nut.
a. Place special tool between the sprockets as shown.
Special Tool: PRIMARY DRIVE LOCKING TOOL
(HD-47977)
b. Tighten clutch hub mainshaft nut (2).
Torque: 94.9-108.5 N·m (70-80 ft-lbs) Clutch hub
mainshaft nut
8.
Install release plate and retaining ring into center of clutch
assembly.
9.
If primary chain tensioner becomes disassembled,
assemble in order shown.
NOTE
Primary chain tensioner is non-repairable. If
tensioner is worn or damaged, replace
assembly.
Chain tensioner is not interchangable with
previous model year parts. Shoe color is black.
a. See Figure 9. Locate end of spring rod (2) on roll pin
(3).
b. See Figure 10. Slide wedge (2) of primary chain
tensioner in direction of arrow until all travel is
removed.
c. See Securing Chain Tensioner. Push shoe (1) down
until it contacts wedge. Keep tension on shoe so
wedge stays in place.
d. Insert cable strap (2) as shown to hold wedge in
place. Verify that end of cable strap hangs below
primary chain tensioner. Cable strap serves as a
reminder to remove before installing primary cover.
10. See Chain Tensioner. Install primary chain tensioner.
a. Install primary chain tensioner (1) with fasteners (2).
Tighten.
Torque: 28.5-32.6 N·m (21-24 ft-lbs) Primary chain
tensioner fasteners
b. Remove cable strap.
11. Set preliminary chain tension.
a. Check tension at the top span while pulling down on
chain midway between sprockets. Correct tension is
Length: 12.7-15.88 mm (0.500-0.625 in)
b. If chain is loose, move chain adjuster one notch.
Check tension.
c. Repeat steps until tension is within specification.
NOTE
Primary chain tensioner will not complete chain
adjustment until vehicle is ridden.
12. Test ride vehicle after tensioner removal/installation to
provide proper adjustment.
1
Chain tensioner shoe
2
Cable strap
Figure 1. Securing Chain Tensioner
1
Chain tensioner
2
Chain tensioner fasteners
3
Cable strap
Figure 2. Chain Tensioner
1
Engine compensating sprocket
2
Primary drive locking tool
3
Clutch sprocket
4
Clutch hub mainshaft nut
Figure 3. Removing Clutch Hub Mainshaft Nut
1
Engine compensating sprocket bolt
2
Primary drive locking tool
Figure 4. Removing Clutch Hub Mainshaft Nut
1
Shaft extension
2
Large spring washer (2)
3
Medium spring washer (2)
4
Small spring washer
5
Sliding cam
6
Compensating sprocket
7
Thrust washer
8
Sprocket retainer
9
Bolt
10
Oil spinner (wide frame only)
Figure 5. Engine Compensating Sprocket Assembly
1
Large spring washer (2)
2
Medium spring washer (2)
Figure 6. Spring Washer Orientation
1
Primary drive locking tool
2
Nut
Figure 7. Installing Clutch Hub Mainshaft Nut
1
Bolt
2
Primary drive locking tool
Figure 8. Installing Engine Compensating Sprocket Bolt
1
Shoe
2
Spring rod
3
Roll pin
Figure 9. Spring Rod Location
1
Shoe
2
Wedge
Figure 10. Primary Chain Tensioner
1. Install primary chaincase cover. See Prepare.
2. Fill primary chaincase with oil. See Change Primary
Chaincase Lubricant.
3. Mid-mount controls: Install foot shift lever. See Shifter
Rod.
4. Install rider footboard and bracket, if removed. See
Prepare.
5. Install negative battery cable. See Main Fuse.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove rider left footboard and bracket, if necessary. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Remove primary chaincase cover. See Prepare.
To replace the entire clutch assembly, see Prepare.
Disassemble
1. See Clutch Shell Assembly. Remove pressure plate
(5).
a.
Remove bolts (1).
b.
Remove springs (3).
c.
Remove spring seats (4).
2. Remove friction and steel plates.
a. Remove narrow friction plates (6) and narrow steel
plate (7).
b. Remove wide friction plates (9) and wide steel
plates (8).
c. Remove narrow friction plate (6).
3. Remove damper spring.
a. Remove damper spring (10).
b. Remove damper spring seat (11).
Clean and Inspect
WARNING
Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air
flow rates. (00061a)
NOTE
Friction and steel plates are only sold as a set.
1.
NOTE
Do not wash friction plates or hub bearing with
cleaning solvent.
Wash parts in cleaning solvent. Dry with low-pressure
compressed air.
2. Check friction plates.
NOTE
Do not use a rag to clean friction plates.
a. Remove lubricant using compressed air.
b. Measure thickness of each plate.
c. If the thickness of any plate is less than the
specification, replace entire clutch disc set.
Length/Dimension/Distance: 3.62 mm (0.143 in)
d. Look for worn or damaged fiber surface material
(both sides).
3.
Check steel plates for distortion.
a. Replace entire clutch disc set if any steel plates are
grooved.
b. Lay plate on a precision flat surface.
c. Using a feeler gauge, check for distortion in several
places.
d. If any steel plate is warped beyond specification,
replace entire clutch disc set.
Length/Dimension/Distance: 0.15 mm (0.006 in)
4.
Check clutch hub bearing for smooth operation. Replace
if necessary. See Disassemble and Assemble: Hub.
5.
Check clutch shell chain sprocket and starter ring gear.
Replace if worn or damaged.
6.
Check clutch hub and shell steel plate slots for wear or
damage. Replace if necessary.
7.
Check coil springs for wear or damage. Replace if
necessary.
Assemble
1. Submerge and soak all friction plates in primary
chaincase lubricant for at least five minutes.
2. See Clutch Shell Assembly. Install Damper spring.
a. Install damper spring seat (11) into clutch hub (12).
b. Install damper spring (10) onto damper spring seat.
3. Install friction and steel plates.
a. Install one narrow friction plate (6) into clutch hub.
b. Install one wide steel plate (8) onto narrow friction
plate and damper spring (10).
c. Beginning with a wide friction plate (9), alternate
remaining wide friction plates (9) with wide steel
plates (8).
d. Install narrow friction plate (6), narrow steel plate (7)
and remaining friction plate (6).
4. Install pressure plate (5).
a. Install spring seats (4).
b. Align and install pressure plate (5) onto clutch hub
(12).
c. Install springs (3).
d. Install bolts (1).
Torque: 8-12 N·m (71-106 in-lbs)
1
Bolt (3)
2
Mainshaft nut
3
Coil spring (3)
4
Seat (3)
5
Pressure plate
6
Narrow friction plate (3)
7
Narrow steel plate (1)
8
Wide steel plate (8)
9
Wide friction plate (7)
10
Damper spring
11
Damper spring seat
12
Clutch hub
13
Clutch shell
Figure 1. Clutch Shell Assembly
Disassemble
WARNING
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers
and could be propelled with enough force to cause serious eye injury. (00312a)
NOTE
Do not disassemble the clutch shell and hub assembly unless the bearing, hub or shell require replacement.
Replace the bearing if disassembled.
1. Press out clutch hub.
a. See Clutch Retaining Rings. Remove clutch hub
retaining ring (2).
b. See Pressing Clutch Hub From Bearing. Support
clutch shell in press with ring gear side up.
c. Press hub from bearing in clutch shell.
2. Remove bearing.
a. See Clutch Retaining Rings. Remove bearing
retaining ring (1) from groove in clutch shell bore.
b. See Pressing Clutch Hub From Bearing. Support
clutch shell in press with ring gear side is down.
c. Use a suitable press plug to remove bearing.
3. Clean and inspect components. See Disassemble and
Assemble: Clutch Pack.
1
Clutch hub retaining ring
2
Bearing retaining ring
3
Bearing
Figure 1. Clutch Retaining Rings
Figure 2. Pressing Clutch Hub From Bearing
Figure 3. Pressing Bearing From Clutch Shell
Assemble
1. Install new bearing.
a. Place clutch shell in press with ring gear side up.
b. Support clutch shell bore on sprocket side to avoid
damage to ears on clutch basket.
c. Using a suitable press plug, press against outer
race until bearing contacts shoulder in clutch shell
bore.
d.
WARNING
Wear safety glasses or goggles when removing
or installing retaining rings. Retaining rings can
slip from the pliers and could be propelled with
enough force to cause serious eye injury.
(00312a)
See Clutch Retaining Rings. Install bearing
retaining ring (1) with flat side toward bearing.
2. Install clutch hub.
a. Place clutch shell in press with sprocket side up.
b. Center the hub in bearing.
c. Support bearing inner race with a sleeve on
transmission side.
d. Press hub into bearing until shoulder contacts
bearing inner race.
e. See Clutch Retaining Rings. Install clutch hub
retaining ring (2) in groove of clutch hub.
1. Install primary chaincase cover. See Prepare.
2. Fill primary chaincase with oil. See Change Primary
Chaincase Lubricant.
3. Mid-mount controls: Install foot shift lever. See Shifter
Rod.
4. Install rider footboard and bracket, if removed. See
Prepare.
5. Install negative battery cable. See Main Fuse.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove rider footboard and bracket, if needed. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Remove primary chaincase cover. See Prepare.
6. Remove starter. See Prepare.
7. Remove primary chain, clutch and compensating sprocket. See Prepare.
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