Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 19
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Commutator
Commutator
Starting groove in mica
Undercutting mica with piece
with 3 cornered file
of hacksaw blade
Mica
Mica
Segments
Wrong way
Right way
Mica must not be left
Mica must be cut away
with a thin edge next to
clean between segments.
segments.
Figure 5-10. Undercutting the Mica Separators
5.
Check the brush length. Brushes less than 0.433 inch
(11 mm) long should be replaced.
CAUTION
Do not use sandpaper or emery cloth on commutator.
NOTE
The abrasive grit may remain on commutator segments
● Replace brushes in sets of four only.
and could cause excessive brush wear.
● Field coil and brush holder brushes are attached to field
10. See Figure 5-11. Check for SHORTED ARMATURE with
coil and brush holder. To replace brushes, replace field
a growler. Place armature on growler. Hold a thin steel
coil and brush holder.
strip (hacksaw blade) against armature core and slowly
turn armature. A shorted armature will cause the steel
6.
See Figure 5-4. Remove armature (9).
strip to vibrate and be attracted to the core. Shorted
armatures should be replaced.
7.
Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.015 in.
(0.38 mm) of runout should be replaced or machined on
2231
a lathe. Commutators should be replaced when diame-
ter is less than 1.141 in. (29.98 mm).
8.
Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.20 mm), use an undercutting machine
to undercut the mica to 1/32 in. (0.79 mm) deep. The
slots should then be cleaned to remove any dirt or cop-
per dust.
9.
See Figure 5-10. If an undercutting machine is not avail-
able, undercutting can be done satisfactorily using a thin
hacksaw blade. After undercutting, lightly sand the
armature with crocus cloth to remove any burrs.
Figure 5-11. Shorted Armature Test Using Growler
2006 Touring: Starter
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11. See Figure 5-12. Check for a GROUNDED ARMATURE
13. See Figure 5-14. Check for GROUNDED FIELD WIND-
with an ohmmeter or continuity tester. Touch one probe
ING with an ohmmeter or continuity tester. Touch one
to any commutator segment, and the other probe to the
probe to the frame, and the other probe to each of the
armature core. There should be no continuity (infinite
brushes attached to the field winding. There should be
ohms). If there is any continuity the armature is
no continuity (infinite ohms). If there is any continuity at
grounded and should be replaced.
either brush, the field winding(s) are grounded and the
field frame should be replaced.
Figure 5-12. Grounded Armature Test
Figure 5-14. Grounded Field Test
12. See Figure 5-13. Check for OPEN ARMATURE with an
14. See Figure 5-15. Check for OPEN FIELD WINDING with
ohmmeter or continuity tester. Check for continuity
an ohmmeter or continuity tester. Touch one probe to the
between all commutator segments. There should be
field wire, and the other probe to each of the brushes
continuity (0 ohms) at all test points. No continuity at any
attached to the field coils. There should be continuity. If
test point indicates armature is open and should be
there is no continuity at either brush, the field winding(s)
replaced.
are open and the field frame should be replaced.
Figure 5-13. Armature Open Test
Figure 5-15. Open Field Test
5-10
2006 Touring: Starter
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15. See Figure 5-16. Test BRUSH HOLDER INSULATION
with an ohmmeter or continuity tester. Touch one probe
f1540a5x
to holder plate and the other probe to each of the posi-
tive (insulated) brush holders. There should be no conti-
nuity (infinite ohms). If there is continuity at either brush
holder, the brush holder assembly should be replaced.
Touch one probe to the non-insulated brush holders and
the other probe to the holder plate. If you measure any
resistance, the brush holder must be replaced.
f1541x5x
Figure 5-18. Drive Housing Assembly
Figure 5-16. Brush Holder Insulation Test
16. Check armature bearings (10) and replace if necessary.
3506
See Figure 5-4.
NOTE
Spring (21) and ball (22) are loose in shaft gear end. See
Figure 5-4.
Figure 5-19. Clutch Assembly
17. See Figures 5-4, 5-17 and 5-18. Remove the two drive
housing mounting screws
(11) and washers
(12).
Remove drive housing (13) from solenoid housing (14).
18. See Figures 5-4 and 5-19. Remove drive (15), idler gear
(16) and idler gear bearing (17) from drive housing (13).
O-ring (18) is in groove in drive housing.
19. Remove spring (19) and shaft (20).
f1557x5x
Figure 5-17. Remove Drive Housing
2006 Touring: Starter
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5.
Lubricate armature bearings (10) with high temperature
ASSEMBLY
grease such as LUBRIPLATE 110. Install armature (9)
and field coil (3) to solenoid housing (14).
1.
See Figure 5-4. Replace O-rings (18, 23).
6.
Replace brush springs (6), if necessary. Install brushes
(7) and brush holder (8).
CAUTION
7.
Install end cap (4) with screws (5).
Do not use solvents to clean drive assembly/over-run-
8.
Install thru-bolts (2).
ning clutch (15). It is lubricated and sealed. If you use a
solvent to clean it, the lubricant will be washed out and
9.
Connect field wire (1) to solenoid terminal. Tighten sole-
the clutch will fail.
noid terminal nut to 70-90 in-lbs (7.9-10.2 Nm).
2.
Clean, inspect and lubricate drive assembly compo-
nents. Lubricate parts with high temperature grease
such as LUBRIPLATE 110.
3.
When installing drive assembly components, open end
of idler bearing cage (17) faces toward solenoid.
4.
When installing drive housing (13) to solenoid housing
(14) use new O-ring (18). Be sure to install return spring
(21) and ball (22).
5-12
2006 Touring: Starter
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STARTER SOLENOID
5.5
2.
Remove cover and gasket. Discard gasket.
GENERAL
3.
Plunger can now be removed from solenoid housing.
The starter solenoid is a switch designed to open and close
the starting circuit electromagnetically. The switch consists of
contacts and a winding around a hollow cylinder containing a
movable plunger. When the winding is energized by the bat-
ASSEMBLY
tery, the magnetism produced pulls the plunger into the coil.
The plunger moves against two main switch contacts, closing
the circuit.
1.
Replace wire connection hardware as necessary.
2.
Apply a light coat of Lubriplate® 110 to plunger shaft.
DISASSEMBLY
Install plunger in solenoid housing.
1.
See Figure 5-20. Remove screws and washers. Clip
3.
Install new gasket. Place cover in position and install
comes off with screw.
screws, washers and clip.
1.
Solenoid Housing
4
2.
Plunger
5
3.
Gasket
7
4.
Cover
3
5.
Clip
6.
Washer
7.
Screw
6
2
1
CAUTION
Do not tighten the inside nut without
removing other items shown. Movement
will cause damage to the contact.
f1079axx
Figure 5-20. Starter Solenoid
2006 Touring: Starter
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STARTER JACKSHAFT
5.6
REMOVAL/DISASSEMBLY
7945
1.
Remove seat. See Section 2.25 SEAT, REMOVAL.
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3.
See Figure 5-21. Remove the primary chaincase cover.
Remove the clutch assembly, primary chain and com-
pensating sprocket components as a single assembly.
See Section 6.5 PRIMARY CHAINCASE, REMOVAL,
steps 3-15.
Starter
NOTE
Jackshaft
Assembly
If only the jackshaft bolt, thrust washer, lockplate, pinion gear
and/or spring require servicing, then the primary chain and
clutch assembly may be left in place.
Figure 5-21. Primary Chaincase
1.
Jackshaft Bolt
14. Output Shaft Coupling
2.
Lockplate
15. Counterbore
13
3.
Tab
16. Primary Cover Bushing
4.
Key
17. Primary Chaincase Bushing
5.
Thrust Washer
6.
Slot
12
14
7.
Pinion Gear
10
8.
Spring
9.
Retaining Ring
15
10. Coupling
8
11. Jackshaft
12. Keyway
11
13. Retaining Ring
6
4
9
17
1
7
16
3
5
2
f1211c5x
Figure 5-22. Starter Jackshaft Assembly
5-14
2006 Touring: Starter
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4.
Bend tab on lockplate away from head of jackshaft bolt.
3.
Install oil filler plug/dipstick at top of transmission case.
See Figure 5-22.
4.
Install slot of exhaust support bracket onto stud of
5.
Holding pinion gear to prevent rotation, remove the jack-
bracket tab aligning other holes with those in starter
shaft bolt with lockplate and thrust washer.
flange. Start Keps nut on stud.
6.
Carefully pull jackshaft assembly from the primary chain-
5.
Engaging hole in exhaust support bracket, install starter
case bore.
front mounting screw with lockwasher. Install rear
mounting screw with lockwasher (and battery negative
7.
Remove the pinion gear from the jackshaft.
cable ring terminal) in the same manner.
8.
Remove the coupling from the jackshaft. Remove the
6.
Alternately tighten starter front and rear mounting
spring from the coupling.
screws to 14-18 ft-lbs (19-24 Nm). Tighten Keps nut on
stud of bracket tab.
CAUTION
7.
Install battery positive and main power cable ring termi-
Do not force the output shaft coupling through the oil
nals onto starter post. Install flange nut and tighten to
seal in the primary chaincase or the resulting damage
70-90 in-lbs (7.9-10.2 Nm). Pull down rubber boot over
will require seal replacement.
terminal connections on starter post.
8.
Snap solenoid connector to terminal at top of starter
9.
From right side of motorcycle, remove starter front
housing.
mounting screw with lockwasher. Remove rear mounting
screw with lockwasher (and battery negative cable ring
NOTE
terminal). Remove Keps nut from stud of bracket tab and
If removed, install allen screw to fasten decorative chrome
remove exhaust support bracket.
cover to starter.
10. Pull back rubber boot and remove flange nut from starter
post. Remove main power and battery positive cable
9.
Inspect the retaining ring within the coupling for damage
ring terminals from starter post.
or distortion. Replace as necessary.
11. Depress external latch and pull solenoid connector from
10.
Insert narrow end of jackshaft into shallow side of cou-
top of starter housing.
pling until gear face contacts installed retaining ring.
(Look at position of retaining ring within coupling to
12. Locate oil filler plug/dipstick at top of transmission case.
determine shallow side.)
To remove the oil filler plug, pull steadily while moving
plug back and forth.
11.
Slide spring over narrow end of jackshaft until it contacts
retaining ring.
13. Remove the starter from the right side of the motorcycle,
carefully sliding it through the space between the
12.
Slide pinion gear over narrow end of jackshaft until it
exhaust pipe and side cover.
contacts spring.
NOTE
13.
Slide lockplate and new thrust washer onto jackshaft
bolt, if removed. Insert bolt into jackshaft bore.
If necessary, remove allen screw and decorative chrome
cover to facilitate starter removal.
14.
Gently insert jackshaft assembly into primary chaincase
so that splined end of shaft engages coupling on starter
14. Remove the coupling from the starter motor output shaft.
output shaft.
15.
Insert key on lockplate through slot in thrust washer and
into keyway on jackshaft. Thread the jackshaft bolt into
ASSEMBLY/INSTALLATION
the starter shaft making sure that the lockplate key
remains in the keyway.
NOTE
16.
Holding pinion gear to prevent rotation, tighten jackshaft
bolt to 60-80 in-lbs (6.8-9.0 Nm). Bend tab on lockplate
To replace the jackshaft bushings and/or seals in the primary
against flat of bolt head to secure.
chaincase or primary chaincase cover, see Section 6.5 PRI-
MARY CHAINCASE, DISASSEMBLY.
17.
Install the clutch, primary chain, and compensating
sprocket components. Install the primary chaincase
1.
Inspect the retaining ring within the output shaft coupling
cover. See Section
6.5 PRIMARY CHAINCASE,
for damage or distortion. Replace as necessary. With the
INSTALLATION, steps 9-31.
counterbore on the outboard side, install the coupling on
the starter motor output shaft, if removed.
18.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
2.
From right side of motorcycle, tilt starter and work into its
bolt to 60-96 in-lbs (6.8-10.9 Nm).
installed position. Starter output shaft coupling must
remain on shaft and mate to starter jackshaft.
19.
Install seat. See Section 2.25 SEAT, INSTALLATION.
2006 Touring: Starter
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NOTES
5-16
2006 Touring: Starter
Table Of Contents
SUBJECT
PAGE NO.
6.1 Specifications
6-1
6.2 Primary Chain And Sprockets
6-3
6.3 Clutch
6-5
6.4 Secondary Drive Belt And Sprockets
6-10
6.5 Primary Chaincase
6-15
DRIVE
6
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SPECIFICATIONS
6.1
OVERALL GEAR RATIOS
SPROCKETS
Overall gear ratios indicate the number of engine revolutions
required to drive the rear wheel one revolution.
Number of Teeth
Sprocket
All Models
Gear
All Models
Engine
25
1
10.11
Clutch
36
2
6.96
Transmission
32
3
4.95
Rear wheel
70
4
3.86
5
3.15
CLUTCH
CHAINS AND BELTS
Clutch
Description
Type
Wet-multiple disc
Primary Chain Adjustments
1/16-1/8 in.
Clutch lever free play
1.6-3.2 mm
Free Play
Inches
Millimeters
loosen 1/2-1 turn after
Clutch screw adjustment
5/8-7/8 inch
15.9-22.2 mm
lightly seating
COLD Engine
HOT Engine
3/8-5/8 inch
9.5-15.9 mm
TORQUE VALUES
Primary Chaincase Lubricant
Item
ft/in-lbs
Nm
Primary chain tensioner
Ounces
Milliliters
21-29 ft-lbs
29-39 Nm
shoe nut
Amount
32
946
Tensioner shoe adjuster
12-14 ft-lbs
16-19 Nm
plate screws
Quart
Primary chain inspection
84-108 in-lbs
10-12 Nm
Part Number
cover screws
99851-05
Clutch adjuster screw
72-120 in-lbs
8-14 Nm
locknut
Rear Belt Adjustment
Clutch inspection cover
84-108 in-lbs
10-12 Nm
screws
Deflection
Inches
Millimeters
Clutch diaphragm spring
90-110 in-lbs
10-12 Nm
retainer to clutch hub bolts
On Jiffy Stand Without
Rear axle cone nut
95-105 ft-lbs
129-142 Nm
1/4 - 5/16
6.4
- 7.9
Rider or Luggage
Rear swingarm pivot
10 psi (69 kPa)
at 10 lbs force
at 4.5 kg force
40-45 ft-lbs
54-61 Nm
shaft locknut
in Rear Shocks
Rear swingarm bracket
Motorcycle Upright
34-42 ft-lbs
46-57 Nm
3/16 - 1/4
4.8
- 6.4
bolts
With Rear Wheel
at 10 lbs force
at 4.5 kg force
Continued ...
in the Air
2006 Touring: Drive
6-1
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TORQUE VALUES (CONT.’D)
Item
ft/in-lbs
Nm
Transmission mainshaft
60 ft-lbs, then
81 Nm, then
sprocket nut
35° to 45°
35° to 45°
Mainshaft sprocket nut
lockplate socket head
84-108 in-lbs
9-12 Nm
screws
Rear wheel sprocket bolts
55-65 ft-lbs
75-88 Nm
Primary chaincase to
15-19 ft-lbs
20.3-25.8 Nm
crankcase/transmission
Starter front and rear
14-18 ft-lbs
19-24 Nm
mounting screws
Starter jackshaft bolt
60-80 in-lbs
6.8-9.0 Nm
Engine compensating
75 ft-lbs, then
101.7 Nm, then
sprocket nut
45° to 50°
45° to 50°
Clutch hub mainshaft nut
70-80 ft-lbs
95-108 Nm
Primary chaincase cover
84-108 in-lbs
9-12 Nm
allen head socket screws
Primary chaincase drain
36-60 in-lbs
4.1-6.8 Nm
plug
Passenger footboard
15-18 ft-lbs
20-24 Nm
socket screws
Heel-toe shift lever
5/16”
18-22 ft-lbs
24-30 Nm
socket screws
Inner shift arm to
shift lever shaft
1/4”
90-110 in-lbs
10.2-12.4 Nm
socket screw
6-2
2006 Touring: Drive
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PRIMARY CHAIN AND SPROCKETS
6.2
PRIMARY CHAIN ADJUSTMENT
Table 6-1. Primary Chain Adjustment
See Section 1.7 PRIMARY CHAIN/LUBRICANT, PRIMARY
(Free Play)
Inches
Millimeters
CHAIN ADJUSTMENT.
COLD ENGINE
5/8-7/8 inch
15.9-22.2 mm
HOT ENGINE
3/8-5/8 inch
9.5-15.9 mm
ADJUSTER SHOE REPLACEMENT
If the nylon adjuster shoe is worn or damaged, replace as fol-
10. If the chain is too tight or too loose, then adjust as fol-
lows:
lows:
1.
Remove the primary chaincase cover. See Section 6.5
a. Loosen the top center nut a maximum of two turns
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
and raise or lower the chain tensioner assembly as
necessary to obtain the specified free play. See Fig-
2.
Loosen top center nut from captured bolt of chain ten-
ure 6-1.
sioner assembly. See Figure 6-1.
NOTE
3.
Lower the chain tensioner assembly until the adjuster
shoe just contacts the inner primary housing.
As chains stretch and wear, they run tighter at one spot than
another. Always adjust the free play at the tightest spot in the
1WARNING
chain. Replace the primary chain if it is worn to the point
where it cannot be properly adjusted.
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
CAUTION
worn. Slippage may propel the ring with enough force to
Always keep the primary chain properly adjusted. Allow-
cause eye injury.
ing the chain to run too tight or too loose will result in
4.
Remove retaining ring from nub and pull adjuster shoe
excessive chain and sprocket wear.
from chain tensioner. Discard adjuster shoe and retain-
ing ring.
5.
Slide new adjuster shoe onto chain tensioner. Be sure
f1840x6x
that the narrow end of the shoe is at the front, the wider
end at the rear.
1
1WARNING
Always wear proper eye protection when installing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
2
worn. Slippage may propel the ring with enough force to
cause eye injury.
6.
Install new retaining ring onto nub of chain tensioner to
lock position of adjuster shoe. Verify that retaining ring is
fully seated in the groove.
7.
Raise the chain tensioner assembly and then snug the
top center nut.
8.
Check the primary chain tension. Push on the upper
3
4
strand to verify that it has free up and down movement
midway between the engine compensating sprocket
1.
Top Center Nut
3.
Adjuster Shoe
(front) and the clutch sprocket (rear).
2.
Primary Chain
4.
Retaining Ring
9.
Measure the free play to be sure that it falls within the
range specified for a hot or cold engine:
Figure 6-1. Primary Chain Tensioner Assembly
2006 Touring: Drive
6-3
HOME
b. Tighten the top center nut of the chain tensioner
ASSEMBLY
assembly to 21-29 ft-lbs (29-39 Nm).
See Section 6.5 PRIMARY CHAINCASE, INSTALLATION,
11. Install the primary chaincase cover. See Section 6.5
steps 9-31.
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
DISASSEMBLY
See Section 6.5 PRIMARY CHAINCASE, REMOVAL, steps
1-15.
CLEANING AND INSPECTION
1.
Periodically inspect the primary chain for cracked, bro-
ken or badly worn links. Replace as necessary.
2.
Inspect engine compensating sprocket components for
damage or wear. Replace parts as necessary.
3.
Inspect clutch sprocket for damage or wear. If broken or
damaged teeth are found, the clutch shell and sprocket
assembly must be replaced.
6-4
2006 Touring: Drive
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CLUTCH
6.3
2.
Remove six bolts to release diaphragm spring retainer
ADJUSTMENT
from clutch hub. See Figure 6-3.
See Section 1.8 CLUTCH ADJUSTMENT.
3.
Remove diaphragm spring retainer, diaphragm spring
and pressure plate from clutch hub.
4.
Remove friction plates, steel plates, damper spring and
REMOVAL/INSTALLATION
damper spring seat from clutch hub.
5.
See CLEANING AND INSPECTION in this section.
To remove the clutch without disassembly, see Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 1-15.
For installation instructions, see Section
6.5 PRIMARY
ASSEMBLY
CHAINCASE, INSTALLATION, steps 9-31.
CLUTCH PACK ONLY
NOTE
If only the clutch pack is to be disassembled, see PARTIAL
1.
Submerge and soak all friction and steel plates in PRI-
DISASSEMBLY below, a procedure that can be performed on
MARY CHAINCASE LUBRICANT for at least five min-
the motorcycle without removing the clutch shell or hub.
utes.
For complete disassembly of the clutch, which includes
2.
Install the narrow friction plate on the clutch hub engag-
clutch pack disassembly and bearing replacement, see
ing tabs on plate with slots in clutch shell.
COMPLETE DISASSEMBLY.
3.
Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.
PARTIAL DISASSEMBLY
4.
Install damper spring on clutch hub with the concave
CLUTCH PACK ONLY
side up (facing opposite damper spring seat). See Fig-
ure 6-2.
1.
Remove the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, REMOVAL, steps 1-8.
5.
Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
alternating between steel plates and friction plates.
f1523x6x
6.
Install pressure plate on clutch hub aligning holes in
5
2
plate with threaded bosses on hub.
7.
Seat diaphragm spring in recess of pressure plate with
1
the concave side down.
6
8.
Align holes in diaphragm spring retainer with threaded
bosses on clutch hub. Tabs on spring retainer contact
flats on inboard side of bosses.
9.
Install six bolts to secure diaphragm spring retainer to
clutch hub. Alternately tighten bolts to
90-110 in-lbs
(10.2-12.4 Nm).
10.
Install the primary chaincase cover. See Section 6.5
PRIMARY CHAINCASE, INSTALLATION, steps 20-31.
3
4
CLEANING AND INSPECTION
1.
Clutch Shell
4.
Damper Spring Seat
1.
Wash all parts in cleaning solvent, except for friction
2.
Clutch Hub
5.
Damper Spring
plates and bearing, if removed. Blow dry with com-
3.
Narrow Friction Plate
6.
Steel Plate
pressed air.
2.
Check friction plates as follows:
Figure 6-2. Clutch Pack Stack-Up (Cut-Away View)
2006 Touring: Drive
6-5
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f1514x6x
5
6
4
2
3
7
8
1
9
10
11
17
16
14
18
15
19
12
23
20
13
21
1.
Retaining Ring
24
2.
Clutch Shell
22
3.
Bearing
10. Damper Spring
4.
Retaining Ring
11. Damper Spring Seat
5.
Clutch Hub
12. Pressure Plate
17. Retaining Ring
6.
Mainshaft Nut
13. Diaphragm Spring
18. Locknut
7.
Friction Plate (9)
14. Diaphragm Spring Retainer
19. Adjuster Screw
22. Thrust Washer (2)
8.
Steel Plate (8)
15. Bolt (6)
20. Push Rod
23. Throw Out Bearing
9.
Narrow Friction Plate
16. Release Plate
21. Oil Slinger
24. Retaining Ring
Figure 6-3. Clutch Assembly
6-6
2006 Touring: Drive
HOME
● Wipe all lubricant from the friction plates. Measure
the thickness of each plate with a dial caliper or
micrometer. If the thickness of any plate is less than
A
0.143 inch (3.62 mm), discard the friction plates and
replace with an entirely new set.
● Look for worn or damaged fiber surface material
(both sides).
NOTE
Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage.
3.
Check steel plates as follows:
● Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
● Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
f1519x6x
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
f1522x6x
0.006 inch (0.15 mm).
B
4.
See Figure 6-3. Holding the clutch hub, rotate the clutch
shell to check bearing for smoothness. Replace the
bearing if it runs rough or binds.
5.
Check the primary chain sprocket and the starter ring
gear on the clutch shell. Replace the clutch shell if either
sprocket or ring gear are badly worn or damaged.
6.
Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace shell or hub if slots are
worn or damaged.
7.
Check the diaphragm spring and diaphragm spring
retainer for cracks or bent tabs. Obtain a new diaphragm
spring or diaphragm spring retainer if either condition
exists.
COMPLETE DISASSEMBLY
CLUTCH PACK AND BEARING
1.
Remove clutch assembly from the motorcycle. See Sec-
A
Remove retaining ring from clutch hub.
tion 6.5 PRIMARY CHAINCASE, REMOVAL, steps 1-15.
B
Press clutch hub from bearing.
2.
Remove six bolts to release diaphragm spring retainer
from clutch hub. See Figure 6-3.
Figure 6-4. Remove Clutch Hub from Clutch Shell
3.
Remove diaphragm spring retainer, diaphragm spring
and pressure plate from clutch hub.
4.
Remove friction plates, steel plates, damper spring and
1WARNING
damper spring seat from clutch hub.
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
CAUTION
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
To avoid possible bearing damage, do not disassemble
cause eye injury.
the clutch shell and hub assembly unless the bearing,
hub or shell require replacement. Replace the bearing if
5.
With the sprocket side up, remove retaining ring from
disassembled.
clutch hub groove. See upper frame of Figure 6-4.
2006 Touring: Drive
6-7
HOME
9.
See CLEANING AND INSPECTION in this section.
C
ASSEMBLY
CLUTCH PACK AND BEARING
1.
Orient clutch shell in arbor press with sprocket side
down. Be sure to support clutch shell bore on sprocket
side. Using a suitable press plug, press against outer
race until bearing contacts shoulder in clutch shell bore.
1WARNING
Always wear proper eye protection when installing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
f1521x6x
cause eye injury.
f1520x6x
NOTE
D
Note that one side of the retaining ring is beveled. Always
install the ring with the beveled side opposite the bearing.
2.
Install retaining ring in groove of clutch shell bore, so
that the flat side of the ring is in towards the bearing, the
beveled side out.
3.
Center hub in bearing. Be sure that bearing inner race is
supported with sleeve on sprocket side. Press hub into
bearing until hub shoulder contacts bearing inner race.
4.
Turn assembly over so that the sprocket side is up.
Install retaining ring in groove of clutch hub.
5.
Place clutch assembly on bench oriented with the
sprocket side down.
6.
Submerge and soak all friction and steel plates in PRI-
MARY CHAINCASE LUBRICANT for at least five min-
utes.
Narrow Plate
C Remove retaining ring from clutch shell.
D Press bearing from clutch shell.
Figure 6-5. Remove Bearing from Clutch Shell
6.
Supporting clutch shell in same orientation, use arbor
press and a suitable press plug to press hub from bear-
ing in clutch shell. See lower frame of Figure 6-4.
7.
Turn clutch shell over so that the sprocket side is down.
Remove retaining ring from groove in clutch shell bore.
See upper frame of Figure 6-5.
8.
Turn clutch shell over so that sprocket side is up. Using
arbor press and a suitable press plug, press on inner
Regular Plate
f1513x6x
race to remove bearing from clutch shell bore. See lower
frame of Figure 6-5.
Figure 6-6. Friction Plates
6-8
2006 Touring: Drive
HOME
7.
Install the narrow friction plate on the clutch hub engag-
14. Install six bolts to secure diaphragm spring retainer to
ing tabs on plate with slots in clutch shell. See Figure 6-
clutch hub. Alternately tighten bolts to
90-110 in-lbs
6.
(10.2-12.4 Nm).
8.
Install damper spring seat on clutch hub so that it seats
15. Install clutch assembly on motorcycle. See Section 6.5
inboard of narrow friction plate.
PRIMARY CHAINCASE, INSTALLATION, steps 9-31.
9.
Install damper spring on clutch hub with the concave
side up (facing opposite damper spring seat). See Fig-
ure 6-2.
10. Install a steel plate and then a friction plate on the clutch
hub. Install seven remaining sets in the same manner,
alternating between steel plates and friction plates.
11. Install pressure plate on clutch hub aligning holes in
plate with threaded bosses on hub.
12. Seat diaphragm spring in recess of pressure plate with
the concave side down.
13. Align holes in diaphragm spring retainer with threaded
bosses on clutch hub. Tabs on spring retainer contact
flats on inboard side of bosses.
2006 Touring: Drive
6-9
HOME
SECONDARY DRIVE BELT AND SPROCKETS
6.4
ADJUSTMENT
DRIVE BELT/TRANSMISSION SPROCKET WEAR
See Section 1.10 DRIVE BELT.
Look for
Cracks Here
Sliding
High-Pressure
Contact Here
Drive Belt
CLEANING AND INSPECTION
Tensile Cords
1.
Use a spray solution of soap and water to clean belt.
Avoid immersion. Wipe the belt down or blow dry.
Worn Tooth
Although the belt's urethane compound is resistant to
Profile
most solvents, these should only be used on a limited
basis, and then must always be followed by a soap and
water wash.
2.
Inspect the edges of the belt for cuts or unusual wear
patterns. While some beveling of the outside edge is
Transmission
common, and by itself is not usually harmful, it is an indi-
Sprocket
cation of sprocket misalignment.
f1632x6x
3.
Inspect the outside ribbed surface of the belt for signs of
stone puncture. Since it is not always easy to observe
this type of damage, look closely.
DRIVE BELT WEAR
f1651x6x
4.
On the inside of the belt, inspect the roots of the belt
teeth to see if the tensile cords are exposed. See upper
frame of Figure 6-7. The tensile cords are covered by a
layer of nylon facing and another layer of polyethylene.
Internal Tooth Crack
Pack Man Cracks
Once these layers are worn through, the tensile cords
(Hairline)
Replace Belt
become visible. Visible tensile cords are an indication
OK to Run, But Monitor
that the transmission sprocket tooth tip diameter is
severely worn. Furthermore, belt failure is imminent,
since the tooth tips will continue to scratch away at the
tensile cords until the belt is completely worn through.
NOTE
During initial operation, the thin coating of polyethylene will
Missing Teeth
Chipping
Replace Belt
(Not Serious)
wear off as it is burnished into the belt fabric. This is a normal
OK to Run, But Monitor
condition and not an indication of belt wear.
5.
Look for signs of cracking at the base of the belt teeth
where contact may be made with the “corners” of worn
transmission sprocket teeth. See upper frame of Figure
6-7. Replace the belt if cracking is evident.
Fuzzy Edge Cord
Hook Wear
NOTE
(Not Serious)
Replace Belt
If the belt is replaced for reasons other than stone damage,
OK to Run, But Monitor
the transmission and/or rear wheel sprockets also should be
replaced. Use of worn or damaged sprockets will severely
Cross-Sectional View
affect belt service life.
6.
For common types of belt wear and damage, see lower
frame of Figure 6-7.
Stone Damage
Bevel Wear
Replace Belt
(Outboard Edge Only)
if Damage on Edge
OK to Run, But Monitor
Figure 6-7. Drive Belt/Transmission Sprocket Wear
6-10
2006 Touring: Drive