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Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 22

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DISASSEMBLY

CAUTION

See Figure 6-11. Turn compressing tool handle only

enough to remove retaining ring (19) and spring seat

PART NO.

SPECIALTY TOOL

(18). Excessive compression of diaphragm spring could

damage clutch pressure plate.

HD-38515-91

Clutch spring forcing screw

3. See Figure 6-11. With a wrench on the clutch spring forc-

HD-38515-A

Spring compressing tool

ing screw flats to prevent the forcing screw from turning,

turn handle clockwise until tool relieves pressure on

NOTES

retaining ring (19) and spring seat (18).

● See Figure 6-11. If replacement of clutch pack (28) is the

4. Remove and discard retaining ring. Remove spring seat

only service work required, perform DISASSEMBLY

from the groove in clutch hub (5) prongs. Remove the

Steps 2 - 5 and 7 only, and then proceed to the NOTE

assembly of diaphragm spring (17), pressure plate (11),

under INSPECTION AND REPAIR.

adjusting screw components (12, 13, 14 and 15) and

compressing tool.

● Observe all 1WARNING and 1CAUTION state-

5. Turn the compressing tool handle counterclockwise until

ments which apply to the steps specified.

the clutch spring forcing screw disconnects from the

clutch adjusting screw. Remove spring seat and dia-

1.

See Figure 6-11. With clutch assembly removed from pri-

phragm spring from pressure plate assembly.

mary chaincase, reinstall adjusting screw assembly (12,

13, 14 and 15) into pressure plate (11), noting that two

6. Remove retaining ring (16) and adjusting screw assem-

tabs on perimeter of release plate (15) must be inserted

bly from pressure plate. If necessary, disassemble

into corresponding recesses in pressure plate. Secure

adjusting screw assembly by removing retaining ring

the adjusting screw assembly with retaining ring (16).

(14), and then separating the remaining adjusting screw

components (12, 13, and 15).

7. Remove the clutch pack (28) from the clutch hub. The

1WARNING

clutch pack consists of one spring plate (8), six steel

Disassemble clutch using a spring compressing tool.

plates (9), and eight friction (fiber) plates (10).

The diaphragm spring is compressed and, if removed

without proper tools can fly out, which could result in

CAUTION

death or serious injury. (00292a)

See Figure 6-11. Due to the possible damage to the bear-

2.

Thread the CLUTCH SPRING FORCING SCREW (item

ing (3), the clutch hub (5) and shell (2) assembly should

1, Figure 6-13.) onto the clutch adjusting screw (item 12,

not be disassembled unless the bearing, hub or shell

Figure 6-11.). Place the bridge (item 2, Figure 6-13.) of

require replacement. If the assembly is pressed apart,

SPRING COMPRESSING TOOL against diaphragm

the bearing must be replaced.

spring (item 17, Figure 6-11.). Thread the tool handle

8. If necessary, disassemble clutch shell and clutch hub as

(item 3, Figure 6-13.) onto end of forcing screw.

follows:

a. Remove retaining ring (1) from inboard end of clutch

hub (5).

10314

b. Using an arbor press, separate clutch hub from

4

2

assembly of clutch shell (2), bearing (3), and retain-

ing ring (4).

c. Remove retaining ring

(4) from groove in clutch

shell.

d. Press on the inboard side of bearing (3) outer race

to remove bearing from clutch shell.

1

3

1.

Forcing screw (Part No. HD-38515-91)

2.

Bridge, Spring Compressing Tool

(Part No. HD-38515-A)

3.

Handle

4.

Open-end wrench

Figure 6-13. Compressing Clutch Diaphragm Spring

2006 Sportster: Drive/Transmission

6-13

HOME

f.

See Figure 6-11. Inspect clutch shell ball bearing (3)

INSPECTION AND REPAIR

for smoothness by rotating clutch shell while holding

clutch hub. If bearing is rough or binds, it must be

NOTE

replaced.

See Figure 6-11. If replacement of clutch pack (28) is the only

g.

See Figure 6-15. Check the primary chain sprocket

service work required, perform all INSPECTION AND

(3) and the starter ring gear (4) on the clutch shell

REPAIR steps (except Step 2.-f.), and then proceed to the

(1). If either sprocket or ring gear are badly worn or

NOTES under ASSEMBLY.

damaged, replace the clutch shell.

h.

Check the slots (5, 6) that mate with the clutch

1WARNING

plates on both clutch shell and clutch hub (2). If slots

are worn or damaged, replace shell and/or hub.

Compressed air can pierce the skin and flying debris

i.

See Figure 6-11. Check the diaphragm spring (17)

from compressed air could cause serious eye injury.

for cracks or bent tabs. Install a new spring if either

Wear safety glasses when working with compressed air.

condition exists.

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

1.

See Figure 6-11. Wash all parts, except the friction

6252

(driven) plates (10) and bearings (3 and 13), in a non-vol-

atile cleaning solution or solvent. Blow parts dry with low

5

pressure compressed air.

2

2.

Examine the clutch components as follows:

6

a. Inspect all clutch plates for wear and discoloration.

b. Inspect all fiber plates (10) for worn lining surfaces

or checked or chipped linings.

c. Inspect each steel (drive) plate (9) for grooves.

d. Place each steel plate on a flat surface. Using a

feeler gauge, check for flatness in several places.

Replace any plates that are damaged, or warped

more than 0.006 in. (0.15 mm).

e. See Figure 6-14. Wipe the lubricant from the eight

4

friction plates and stack them on top of each other.

Measure the thickness of the eight stacked friction

3

plates with a dial caliper or micrometer. The mini-

1

mum thickness must be 0.661 in. (16.79 mm). If the

thickness is less than specified, the friction plates

1. Clutch shell

and steel plates must be discarded, and a new set

2. Clutch hub

of both friction and steel plates must be installed.

3. Primary chain sprocket

4. Starter ring gear

5. Clutch hub slots

7738

6. Clutch shell slots

Figure 6-15. Checking Clutch Hub and Clutch Shell

Figure 6-14. Measuring Clutch Friction Plates

6-14

2006 Sportster: Drive/Transmission

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3. See Figure 6-11. The clutch pack (28) consists of one

ASSEMBLY

spring plate (8), six steel plates (9) and eight friction

(fiber) plates (10). Install clutch pack into clutch shell in

the following order:

PART NO.

SPECIALTY TOOL

F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F

HD-38515-91

Clutch spring forcing screw

HD-38515-A

Spring compressing tool

(F = Friction plate, St = Steel plate, Sp = Spring plate)

NOTES

4.

See Figure 6-11. Place pressure plate (11) onto clutch

●

See Figure 6-11. If replacement of clutch pack (28) is the

pack (28).

only service work required, perform all ASSEMBLY

5.

If disassembled, assemble bearing (13) and adjusting

Steps except 2, 5 and 6, and then proceed to the NOTE

screw (12) in release plate (15); secure with new retain-

under INSTALLATION.

ing ring (14).

●

Observe all

1WARNING and 1CAUTION state-

6.

Install adjusting screw assembly (12, 13, 14, 15) into

ments which apply to the steps specified.

pressure plate (11), noting that two tabs on perimeter of

release plate (15) must be inserted into corresponding

1.

Submerge and soak all friction and steel plates in GEN-

recesses in pressure plate. Secure adjusting screw

UINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-

assembly with new retaining ring (16).

SION AND PRIMARY CHAINCASE LUBRICANT for at

least five minutes.

7.

Position diaphragm spring (17) with its concave side fac-

ing inboard (toward pressure plate), onto pressure plate

2.

See Figure 6-16. If the clutch hub (1) and clutch shell (4)

assembly.

was disassembled, press new ball bearing (3) into clutch

shell and secure bearing with a new retaining ring (2).

8.

Position spring seat (18) with its flat, larger outer diame-

Press inboard end of clutch hub into clutch shell bearing

ter side facing inboard (toward diaphragm spring).

and secure with a new retaining ring (5) on end of hub.

9.

Install a new retaining ring (19) onto convex (outboard)

side of diaphragm spring.

10.

See Figure 6-11. See Figure 6-13. Thread the CLUTCH

x0570x6x

SPRING FORCING SCREW (item 1, Figure 6-13.) onto

5

4

the clutch adjusting screw (item 12, Figure 6-11.). Place

the bridge

(item

2, Figure

6-13.) of SPRING COM-

PRESSING TOOL against diaphragm spring (item 17,

Figure 6-11.). Thread the tool handle (item 3, Figure 6-

3

13.) onto end of forcing screw. Do not tighten compress-

2

1

ing tool against diaphragm spring at this time.

11.

See Figure 6-17. Align square openings of pressure

plate and diaphragm spring (1) so the assembly can be

installed over prongs of clutch hub (2). Place assembly of

spring seat

(5), retaining ring

(3), diaphragm spring,

pressure plate, adjusting screw components

(4) and

compressing tool onto clutch hub and against clutch

pack (item 28, Figure 6-11.).

1.

Clutch hub

2.

Retaining ring

3.

Ball bearing

4.

Clutch shell

5.

Retaining ring

Figure 6-16. Clutch Hub and Shell Assembly

2006 Sportster: Drive/Transmission

6-15

HOME

INSTALLATION

6253

4

1

PART NO.

SPECIALTY TOOL

HD-38362 or

Sprocket locking link (for correct

HD-46283

application, refer to Table 6-6.)

5

NOTE

See Figure 6-11. If replacement of clutch pack (28) is the only

3

service work required, perform INSTALLATION Step 9 only.

1. See Figure 6-11. Remove retaining ring (16). Remove

2

adjusting screw assembly (12, 13, 14, 15) from pressure

plate (11). This allows installation of the transmission

1.

Diaphragm spring (pressure plate below)

mainshaft nut and washer.

2.

Prongs on clutch hub

NOTE

3.

Retaining ring

Prior to installing engine sprocket nut and transmission main-

4.

Adjusting screw assembly

shaft nut, thoroughly clean threads of engine sprocket shaft,

5.

Spring seat

engine sprocket nut, transmission mainshaft and mainshaft

Figure 6-17. Spring Seat Installation

nut to remove any oil that might contaminate and interfere

with locking agent.

2. Install the engine sprocket, clutch assembly and primary

CAUTION

chain as a unit into primary chaincase.

See Figure 6-11. Turn compressing tool handle only

enough to install spring seat (18) and retaining ring (19).

CAUTION

Excessive compression of diaphragm spring (17) could

damage clutch pressure plate (11).

See Figure 6-18. In the next step, you will be positioning

the SPROCKET LOCKING LINK (Part No. HD-46283 or

12. See Figure 6-13. Place an open-end wrench (4) on the

HD-38362) (1) on the engine and clutch sprockets. Make

clutch spring forcing screw (1) flats to prevent the forcing

sure you do not position the sprocket locking link too

screw from turning.

close to the shifter shaft (2). If the sprocket locking link

13. See Figure 6-11. Turn compressing tool handle clock-

contacts the shifter shaft while you are exerting force to

wise until diaphragm spring

(17) compresses just

tighten the engine sprocket nut, the sprocket locking link

enough to install spring seat (18) and retaining ring (19)

may damage the shifter shaft and/or the engine crank-

into the groove in clutch hub (5) prongs.

case.

14. With retaining ring positioned against flange face (out-

board side) of spring seat and fully seated in groove of

clutch hub, carefully loosen and remove compressing

10312

tool.

2

NOTE

When the compressing tool is removed, the diaphragm spring

will move outward forcing the spring seat up into the inside of

the retaining ring. The spring seat provides an operating sur-

face for the diaphragm spring at the same time preventing the

retaining ring from coming out during operation.

1

1.

Sprocket locking link (Part No. HD-46283 or

HD-38362)

2.

Shifter shaft

Figure 6-18. Using Sprocket Locking Link

(Part No. HD-46283 or HD-38362) to

Tighten Engine Sprocket Nut

6-16

2006 Sportster: Drive/Transmission

HOME

NOTE

8. See Figure 6-20. Install adjusting screw assembly (1) in

For correct sprocket locking link application, refer to Table 6-

pressure plate, noting that two tabs on perimeter of

6.

release plate must be inserted into corresponding

recesses in pressure plate. Secure assembly with a new

3.

See Figure 6-18. Install SPROCKET LOCKING LINK.

retaining ring (2).

4.

Apply two or three drops of LOCTITE Threadlocker 262

9. Install primary cover, adjust primary chain and clutch, fill

(red) onto threads of engine sprocket shaft.

transmission with GENUINE HARLEY-DAVIDSON FOR-

5.

Install engine sprocket nut. Tighten to

190-210 ft-lbs

MULA+ TRANSMISSION AND PRIMARY CHAINCASE

(258-285 Nm).

LUBRICANT and connect battery, as described under

Primary Cover INSTALLATION under 6.3 PRIMARY

CAUTION

CHAIN ADJUSTER.

See Figure 6-19. Washer (2) must be installed with the

word “out” facing the transmission mainshaft nut (1).

10313

Incorrect assembly can result in clutch and/or transmis-

sion failure.

6.

See Figure 6-19. Apply two or three drops of LOCTITE

Threadlocker 262 (red) onto threads on end of transmis-

sion mainshaft. Install spring washer (2) and mainshaft

nut (1) (left-hand threads) on transmission mainshaft.

1

Tighten nut to 70-80 ft-lbs (95.0-108.6 Nm).

7.

Remove SPROCKET LOCKING LINK.

b1060x6x

3

2

2

1

1.

Adjusting screw assembly

2.

Retaining ring

Figure 6-20. Clutch Adjusting Screw Assembly and

Retaining Ring

1.

Mainshaft nut

2.

Spring washer

3.

Clutch hub

Figure 6-19. Mainshaft Nut and Washer

2006 Sportster: Drive/Transmission

6-17

HOME

SECONDARY DRIVE BELT

6.6

REMOVAL

10625

1.

Remove both mufflers and rear exhaust pipe. See

REMOVAL under 2.27 EXHAUST SYSTEM.

3

2

2.

XL 883, XL 883L, XL 883R and XL 1200R models:

Remove right side rider footrest/brake pedal and mount-

ing bracket assembly. See RIGHT FOOTREST AND

REAR BRAKE PEDAL ASSEMBLY under 2.33 RIDER

1

FOOT CONTROLS: XL 883, XL 883L, XL 883R, XL

1200R.

3.

See Figure 6-21. Remove screw (6), washer (5) and

exhaust pipe clamp bracket (4). Remove two screws (2,

3). Remove sprocket cover (1).

4

x0256b6x

1

1.

E-clip

4

2.

Axle adjuster nut (2)

3.

Axle adjuster (2)

5

4.

Axle nut

6

Figure 6-22. Secondary Drive Belt Adjustment

x0578b2x

3

4

1

1.

Sprocket cover

2

2.

Screw

6

3.

Screw

5

7

4.

Exhaust pipe clamp bracket

5.

Washer

3

6.

Screw

Figure 6-21. Sprocket Cover

4.

See Figure 6-22. Remove and discard e-clip (1) and

loosen rear axle nut (4). Decrease belt tension by turning

the axle adjuster nut (2) on each side of rear fork an

equal number of turns counterclockwise.

5.

See Figure 6-23. Remove right lower shock absorber

bolt (2), washer (3) and locknut (1).

2

8

10

9

1.

Nut

2.

Bolt

3.

Washer

4.

Belt guard

5.

Screw

6.

Washer

7.

Nut

8.

Debris deflector

9.

Screw with captive washer (3)

10.

Rear fork

Figure 6-23. Belt Guard/Debris Deflector

6-18

2006 Sportster: Drive/Transmission

HOME

6.

Remove nut (7), screw (5) and washer (6) securing front

of belt guard (4) to rear fork (10). Remove belt guard.

CAUTION

7.

Loosen, but do not remove three screws with captive

See Figure 6-24. All belts, used or new, must never be

washers (9) securing debris deflector (8) to rear fork.

formed into a loop smaller than 5.0 in. (127 mm), and

Slide debris deflector forward until keyway slots in deflec-

must never be bent backwards into a loop smaller than

tor clear screw heads. Remove debris deflector.

10 in. (254 mm). Sharp bending can weaken the belt.

8.

Remove belt.

Used belts must be reinstalled so they rotate in the same

direction as they originally did.

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 6-24. Proper Drive Belt Handling

2006 Sportster: Drive/Transmission

6-19

HOME

TRANSMISSION

6.7

The transmission is foot-operated by the gear shifter lever,

OPERATION

which transmits the force through a gear shifter shaft. The

shifter shaft actuates a pawl and a shifter fork drum. The

See Figure 6-25. The transmission is a five-speed constant-

shifter fork drum moves shifter forks, which slide a series of

mesh type housed in an extension of the crankcase. The

shifter dogs on the mainshaft and countershaft, into and out

transmission permits the rider to vary the ratio of engine

of mesh with the other gears.

speed-to-rear driving wheel speed in order to meet the vary-

ing conditions of operation.

x0259c6x

Mainshaft

Mainshaft

Neutral

1st Gear

2

3 4

1

5

2

3 4

1

5

Countershaft

Countershaft

Mainshaft

Mainshaft

2nd Gear

3rd Gear

2

3 4

1

5

2

3 4

1

5

Countershaft

Countershaft

Mainshaft

Mainshaft

4th Gear

5th Gear

2

3 4

1

5

2

3 4

1

5

Countershaft

Countershaft

- SLIDING MEMBER

- IN

- POWER FLOW

- OUT

Figure 6-25. Transmission Power Flow

2006 Sportster: Drive/Transmission

6-21

HOME

CASE DISASSEMBLY FOR TRANSMISSION REMOVAL

6.8

GENERAL

11474

The rear compartment of the left and right crankcase halves

form the transmission case. Servicing of transmission compo-

1

nents requires removing the engine and disassembling (split-

ting) the crankcase.

ENGINE REMOVAL AND

DISASSEMBLY

1.

Remove engine from chassis. See 3.12 REMOVING

2

ENGINE FROM CHASSIS.

2.

Support engine using ENGINE SUPPORT STAND (Part

No. HD-42310-45, and HD-43646 or HD-43682).

3.

Disassemble top end. See 3.14 TOP END OVERHAUL:

DISASSEMBLY.

4.

Remove primary cover, clutch assembly, primary chain

and engine sprocket. See

6.5 PRIMARY DRIVE/

1.

Neutral indicator switch

CLUTCH.

2.

Neutral switch connector [131]

5.

Disassemble gearcase. See 3.18 BOTTOM END OVER-

Figure 6-27. Neutral Switch and Connector [131]

HAUL: DISASSEMBLY.

6.

Remove transmission sprocket. See 6.15 TRANSMIS-

SION SPROCKET.

11475

7.

See Figure 6-26. Place transmission in 1st gear. Remove

countershaft retaining screw (1).

8.

Place transmission in neutral. See Figure 6-27. Unplug

neutral switch connector [131] (2) by pulling connector

straight off neutral switch (1). Unscrew and remove neu-

tral switch and flat washer.

9.

See Figure 6-28. Ensure shifter drum detent is visible in

neutral switch hole indicating that transmission is in neu-

tral.

11315

Figure 6-28. Shifter Drum Neutral Detent

2

1

1.

Countershaft retaining screw

2.

Shifter shaft assembly

Figure 6-26. Countershaft Retaining Screw

6-22

2006 Sportster: Drive/Transmission

HOME

10. See Figure 6-29. See Figure 6-30. Depress ratchet arms

11. Remove starter. See 5.4 STARTER MOTOR.

(item 2, Figure 6-29.) in order to clear the shifter drum,

12. See Figure 6-31. With transmission still in neutral, scribe

and remove shifter shaft assembly from left crankcase

a line on the end of the shifter drum at the 12 o’clock

half.

position for later reference.

8626

11318

3

1

2

1.

Shifter shaft

2.

Ratchet arms

3.

Return spring

Figure 6-29. Shifter Shaft Assembly

11316

Figure 6-31. Scribed Line on Shifter Drum at 12 o’clock

(Transmission in Neutral)

Figure 6-30. Removing Shifter Shaft Assembly

2006 Sportster: Drive/Transmission

6-23

HOME

x0568a3x

x0659x3x

Left side

Right side

- Indicates crankcase fastener locations

– Short fastener

Figure 6-32. Crankcase Fasteners

NOTE

NOTE

New crankcase assembly has 17 fasteners; 15 inserted from

Flywheel assembly slides off left main bearing by hand. No

left side and two inserted from right side. Make certain all fas-

tools are required for this operation.

teners have been removed before attempting to separate

15. See Figure 6-34. Remove flywheel assembly from right

crankcase halves.

crankcase half.

13. See Figure 6-32. Remove 15 crankcase fasteners (11

long and four short) from left side of crankcase assembly.

Remove two fasteners from right side of crankcase

11522

assembly.

14. Tap crankcase gently with rawhide mallet to loosen and

separate the halves. See Figure

6-33. Remove left

crankcase assembly with transmission.

11538

Figure 6-34. Removing Flywheel Assembly

From Right Crankcase Half

Figure 6-33. Separating Crankcase Halves

6-24

2006 Sportster: Drive/Transmission

HOME

TRANSMISSION REMOVAL AND DISASSEMBLY

6.9

1. See Figure 6-36. Remove shifter fork shafts by inserting

TRANSMISSION REMOVAL FROM

a small flat punch in the slots and tapping on the end of

LEFT CRANKCASE

each shaft until it falls free.

NOTE

Carefully tap on alternate sides of the shaft-end using the

provided slots.

PART NO.

SPECIALTY TOOL

2. See Figure 6-37. Remove shifter drum (1) and shifter

B-43985-1

Transmission remover

forks (2). Mark each shifter fork as it is removed, so it can

be reinstalled in the same location.

NOTE

See Figure 6-35. Shifter design allows for one common part

number for both countershaft shifter forks. But as the trans-

mission runs, each shifter fork develops a certain wear pat-

11319

tern with its mating parts. For this reason, it is important that

each shifter fork be reinstalled in its original location.

11321

4/5

Figure 6-36. Slots For Removing Shifter Fork Shafts

Mainshaft

11320

2

3

Left

Right

1

2-3

1

2

4

5

Countershaft

1.

Shifter drum

Figure 6-35. Shifter Forks, Drum and Shafts

2.

Shifter fork (3)

3.

Mainshaft

4.

Mainshaft 2nd gear

5.

Countershaft

Figure 6-37. Transmission Assembly

2006 Sportster: Drive/Transmission

6-25

HOME

x0571a6x

18

19

20

17

22

21

15

16

13

5

12

11

10

4

14

7

6

3

4

2

9

1

8

1.

Detent spring

12. Bushing

2.

Detent spring sleeve assembly

13. Shifter stop pin

3.

Screw

14. Shifter return spring

4.

Shifter fork shaft (2)

15. Extension spring

5.

Shifter fork (4th/5th)

16. Shifter lever assembly

6.

Right hand crankcase bushing

17. Rubber washer

7.

Shifter cam assembly

18. Screw

8.

Shifter fork (1st)

19. Washer

9.

Shifter fork (2nd/3rd)

20. Foot shift lever

10. Retaining ring

21. Shifter peg

11. Bearing

22. Oil seal

Figure 6-38. Shifter Mechanism

6-26

2006 Sportster: Drive/Transmission

HOME

3.

See Figure 6-39. Place left crankcase (3) and transmis-

MAINSHAFT/COUNTERSHAFT

sion assembly (4) on press bed. Support crankcase on

two parallel supports (5).

NOTES

4.

Press transmission assembly using TRANSMISSION

● As the transmission runs, each part develops a certain

REMOVER (2) to remove transmission assembly from

wear pattern and a kind of “set” with its mating parts. For

crankcase half.

this reason, it is important that each component be rein-

5.

Remove crankcase from press.

stalled in its original location and facing its original direc-

tion.

● See Figure 6-40. As each component is removed, place

11322

it on a clean surface in the exact order of removal.

11331

2

1

3

5

4

6

Figure 6-40. Transmission Parts Identification

1.

Press ram

2.

Transmission remover (Part No. B-43985-1)

3.

Crankcase

4.

Transmission assembly (countershaft visible)

5.

Parallel Support (2)

6.

Press bed

Figure 6-39. Pressing Transmission From Left Crankcase

2006 Sportster: Drive/Transmission

6-27

HOME

17

x0572b6x

16

15

14

13

12

11

8

9

10

32

6

7

31

6

30

5

29

3

4

2

1

9

10

10

9

9

10

28

12

27

12

20

19

25

26

18

24

12

23

22

21

1.

Oil seal

17.

Retaining ring

2.

Retaining ring

18.

Closed end bearing

3.

Ball bearing

19.

Countershaft 5th gear**

4.

O-ring

20.

Countershaft

5.

Oil seal

21.

Countershaft 1st gear

6.

Needle bearing (2)

22.

Dog ring

7.

Mainshaft 5th gear

23.

Countershaft 4th gear

8.

Mainshaft 1st gear

24.

Countershaft 3rd gear

9.

Retaining ring (4)

25.

Dog ring

10.

Thrust washer (4)

26.

Thrust washer

11.

Mainshaft 4th gear

27.

Countershaft 2nd gear

12.

Split bearing (4)

28.

Spacer

13.

Mainshaft

29.

Countershaft bearing

14.

Mainshaft 3rd gear*

30.

Retaining ring

15.

Mainshaft 2nd gear*

31.

Countershaft retaining screw

16.

Mainshaft bearing

32.

Retaining ring

* Mainshaft 2nd and 3rd gears are integral to the shaft.

** Countershaft 5th gear is integral to the shaft.

Figure 6-41. Transmission Assembly

6-28

2006 Sportster: Drive/Transmission

HOME

1. See Figure 6-42. Remove 1st gear (1).

MAINSHAFT DISASSEMBLY

2. Use RETAINING RING PLIERS to expand and remove

retaining ring (2). Discard retaining ring.

3. Slide thrust washer (3) off end of mainshaft.

PART NO.

SPECIALTY TOOL

4. Remove 4th gear (4) and split bearing (5). Discard bear-

J-5586

Retaining ring pliers

ing.

NOTES

Cleaning And Inspection

● Mainshaft 2nd and 3rd gears are integral to the shaft.

● Mainshaft

1st gear is directional. Mark gear when

1WARNING

removed for correct installation.

Compressed air can pierce the skin and flying debris

● Once the transmission assembly has been pressed out

from compressed air could cause serious eye injury.

of the left crankcase half, the mainshaft and countershaft

Wear safety glasses when working with compressed air.

assemblies can be serviced separately.

Never use your hand to check for air leaks or to deter-

● All thrust washers are one common part number. This

mine air flow rates. (00061a)

transmission requires no shimming.

1. Clean all parts in cleaning solvent and blow dry with low

pressure compressed air.

1WARNING

2. Check gear teeth for damage. If gears are pitted, scored,

rounded, cracked or chipped, they should be replaced.

Wear safety glasses or goggles when removing or install-

3. Inspect the engaging dogs on the gears. Replace the

ing retaining rings. Retaining rings can slip from the pli-

gears if dogs are rounded, cracked, battered, chipped or

ers and could be propelled with enough force to cause

dimpled.

serious eye injury. (00312a)

NOTE

Use correct retaining ring pliers and correct tips. Verify that

tips are not excessively worn or damaged.

x0599a6x

Left Crankcase

6

1

3

5

8

2

7

4

1.

Mainshaft 1st gear

5.

Split bearing

2.

Retaining ring

6.

Mainshaft

3.

Thrust washer

7.

Mainshaft 3rd gear*

4.

Mainshaft 4th gear

8.

Mainshaft 2nd gear*

* Mainshaft 2nd and 3rd gears are integral to the shaft.

Figure 6-42. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly

2006 Sportster: Drive/Transmission

6-29

HOME

3. Remove dog ring (15).

COUNTERSHAFT DISASSEMBLY

4. Using RETAINING RING PLIERS, expand and remove

retaining ring (14). Discard retaining ring.

5. Remove thrust washer (13), 3rd gear (12), and split bear-

PART NO.

SPECIALTY TOOL

ing (11). Discard bearing.

J-5586-A

Retaining ring pliers

6. Remove thrust washer (10).

NOTES

7. Expand, remove and discard retaining ring (9).

● Countershaft 5th gear is integral to the shaft.

8. Remove 4th gear (8) and dog ring (7).

● Once the transmission assembly has been pressed out

of the left crankcase half, the mainshaft and countershaft

9. Expand, remove and discard retaining ring (6).

assemblies can be serviced separately.

10. Remove thrust washer (5), 1st gear (4) and split bearing

● All thrust washers are one common part number. This

(3). Discard bearing.

transmission requires no shimming.

Cleaning And Inspection

1WARNING

1WARNING

Wear safety glasses or goggles when removing or install-

ing retaining rings. Retaining rings can slip from the pli-

Compressed air can pierce the skin and flying debris

ers and could be propelled with enough force to cause

from compressed air could cause serious eye injury.

serious eye injury. (00312a)

Wear safety glasses when working with compressed air.

NOTE

Never use your hand to check for air leaks or to deter-

Use correct retaining ring pliers and correct tips. Verify that

mine air flow rates. (00061a)

tips are not excessively worn or damaged.

1. Clean all parts in cleaning solvent and blow dry with low

1.

See Figure 6-43. Remove spacer (19) and 2nd gear (18)

pressure compressed air.

from the end of the of the countershaft (2). Remove and

2. Check gear teeth for damage. If gears are pitted, scored,

discard split bearing (17).

rounded, cracked or chipped, they should be replaced.

2.

Remove spacer (16).

3. Inspect the engaging dogs on the gears. Replace the

NOTE

gears if dogs are rounded, cracked, battered, chipped or

When removing the dog ring (15), it is important to mark the

dimpled.

direction of the ring on the shaft as parts establish wear pat-

terns.

x0600a6x

Left Crankcase

5

6

9

10

13

14

2

1

3

4

11

7

8

12

15

16

17

18

19

1.

Countershaft 5th gear*

8.

Countershaft 4th gear

15. Dog ring

2.

Countershaft

9.

Retaining ring

16. Spacer

3.

Split bearing

10. Thrust washer

17. Split bearing

4.

Countershaft 1st gear

11. Split bearing

18. Countershaft 2nd gear

5.

Thrust washer

12. Countershaft 3rd gear

19. Spacer

6.

Retaining ring

13. Thrust washer

7.

Dog ring

14. Retaining ring

* Countershaft 5th gear is integral to the shaft.

Figure 6-43. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly

6-30

2006 Sportster: Drive/Transmission

HOME

TRANSMISSION ASSEMBLY

6.10

GENERAL

MAINSHAFT ASSEMBLY

NOTE

Use correct retaining ring pliers and correct tips when assem-

PART NO.

SPECIALTY TOOL

bling transmission. Verify that tips are not excessively worn or

damaged.

J-5586-A

Retaining ring pliers

CAUTION

1WARNING

During assembly, the split bearings and the internal

Wear safety glasses or goggles when removing or install-

bores of the gears must be lubricated with GENUINE

ing retaining rings. Retaining rings can slip from the pli-

HARLEY-DAVIDSON FORMULA+ TRANSMISSION AND

ers and could be propelled with enough force to cause

PRIMARY CHAINCASE LUBRICANT prior to assembly.

serious eye injury. (00312a)

Leaving these parts dry could accelerate wear at start-

up.

1. See Figure 6-44. Install new split bearing (5) in 4th gear

position on mainshaft.

2. Install 4th gear (4) and thrust washer (3).

3. Using RETAINING RING PLIERS, expand and install

new retaining ring (2).

4. Install 1st gear (1).

x0599a6x

Left Crankcase

6

1

3

5

8

2

7

4

1.

Mainshaft 1st gear

5.

Split bearing

2.

Retaining ring

6.

Mainshaft

3.

Thrust washer

7.

Mainshaft 3rd gear*

4.

Mainshaft 4th gear

8.

Mainshaft 2nd gear*

* Mainshaft 2nd and 3rd gears are integral to the shaft.

Figure 6-44. Transmission Mainshaft Assembly/Reassembly

2006 Sportster: Drive/Transmission

6-31

HOME

1. See Figure 6-45. Install new split bearing (3) in 1st gear

COUNTERSHAFT ASSEMBLY

position on mainshaft.

2. Install 1st gear (4) and thrust washer (5).

3. Using RETAINING RING PLIERS, expand and install

PART NO.

SPECIALTY TOOL

new retaining ring (6).

4. Install dog ring (7) onto 4th gear (8). Now install dog ring

J-5586-A

Retaining ring pliers

and gear assembly onto countershaft.

5. Expand and install new retaining ring (9).

1WARNING

6. Install thrust washer (10).

Wear safety glasses or goggles when removing or install-

7. Install new split bearing (11) in 3rd gear position on

ing retaining rings. Retaining rings can slip from the pli-

mainshaft.

ers and could be propelled with enough force to cause

8. Install 3rd gear (12) and thrust washer (13).

serious eye injury. (00312a)

9. Expand and install new retaining ring (14).

NOTE

10. Install dog ring (15). Make sure to install with dog ring

Use correct retaining ring pliers and correct tips. Verify that

facing same direction as when it was removed.

tips are not excessively worn or damaged.

11. Install spacer (16).

12. Install new split bearing (17) in 2nd gear position on

CAUTION

shaft.

During assembly, the split bearings and the internal

13. Install 2nd gear (18) and spacer (19).

bores of the gears must be lubricated with GENUINE

NOTE

HARLEY-DAVIDSON FORMULA+ TRANSMISSION AND

At this point both mainshaft and countershaft sub-assemblies

PRIMARY CHAINCASE LUBRICANT prior to assembly.

are ready to be pressed into the left crankcase half.

Leaving these parts dry could accelerate wear at start-

up.

x0600a6x

Left Crankcase

5

6

9

10

13

14

2

1

3

4

11

7

8

12

15

16

17

18

19

1.

Countershaft 5th gear*

8.

Countershaft 4th gear

15. Dog ring

2.

Countershaft

9.

Retaining ring

16. Spacer

3.

Split bearing

10. Thrust washer

17. Split bearing

4.

Countershaft 1st gear

11. Split bearing

18. Countershaft 2nd gear

5.

Thrust washer

12. Countershaft 3rd gear

19. Spacer

6.

Retaining ring

13. Thrust washer

7.

Dog ring

14. Retaining ring

* Countershaft 5th gear is integral to the shaft.

Figure 6-45. Transmission Countershaft Assembly/Reassembly

6-32

2006 Sportster: Drive/Transmission

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