Harley Davidson FLHRC 2006. Maintenance & Repair Manual

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REPLACEMENT

INSTALLATION

CAUTION

REMOVAL

Handle the drive belt with care. Never bend belt forward

into a loop smaller than five inches (127 mm) diameter.

Remove rear wheel and rear swingarm. See Section

Never bend belt into a reverse loop smaller than ten

2.20 REAR SWINGARM, REMOVAL.

inches (254 mm) diameter. Over bending will weaken belt

and result in premature failure. Always install belt in the

Remove the primary chaincase assembly. See Section

same direction of rotation as when it was removed. For

6.5 PRIMARY CHAINCASE, REMOVAL.

other handling tips, see Figure 6-8.

Remove the old belt from the transmission sprocket.

Install the new belt on the transmission sprocket.

Forward bend must not be less than 5 in. (127 mm).

Reverse bend must not be less than 10 in. (254 mm).

Minimum Diameter

Do not twist.

Do not crimp, pinch or kink.

Do not pry.

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 6-8. Proper

Drive Belt Handling

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Install the primary chaincase assembly. See Section 6.5

Carefully inspect the sprocket for cracks or other dam-

PRIMARY CHAINCASE, INSTALLATION.

age.

Install rear swingarm and rear wheel. Adjust belt deflec-

Inspect the sprocket for heavy pitting, which indicates a

tion. See Section 2.20 REAR SWINGARM, INSTALLA-

high degree of abrasive wear.

TION.

Look for “sharp” corners at the top of each sprocket

tooth, particularly where the flank joins the top radius. A

smooth transition should exist between the flank and

radius. While worn teeth will appear to have an edge

TRANSMISSION SPROCKET

across the face width of the tooth, heavily worn teeth will

have a flat across the top. If the flat is 1/8 inch (3 mm)

wide or more, replace the transmission sprocket and

REMOVAL

drive belt. See upper frame of Figure 6-7.

Remove rear wheel. See Section 2.4 REAR WHEEL,

REMOVAL.

Remove the primary chaincase assembly. See Section

INSTALLATION

6.5 PRIMARY CHAINCASE, REMOVAL.

Install the transmission sprocket (with belt) on the main

See Figure 6-9. Remove the two socket screws and

drive gear.

lockplate to free the sprocket nut.

Install the sprocket nut. The following procedure is based

NOTE

on whether a new or used nut is being installed.

The transmission sprocket nut has left handed threads. Turn

the nut clockwise to remove from the main drive gear.

CAUTION

Remove the sprocket nut. Use an air impact wrench for

Exercise caution to avoid getting oil on the threads of

best results.

the sprocket nut or the integrity of the lock patch may be

compromised.

CLEANING AND INSPECTION

New sprocket nut: smear a small quantity of clean

engine oil on the inside face of the sprocket nut and the

Using a non-volatile cleaning solvent, thoroughly clean

outside face of the sprocket. Limit the application to

the transmission sprocket of all grease and dirt.

where the surfaces of the two parts contact each other.

Install the sprocket nut until finger tight.

NOTE

The transmission sprocket nut has left handed threads. Turn

the nut counterclockwise to install on the main drive gear.

Used sprocket nut: apply Loctite High Strength Thread-

locker 262 (red) to the threads of the sprocket nut. Also

smear a small quantity of Loctite or clean engine oil on

the inside face of the sprocket nut and the outside face

of the sprocket. Limit the application to where the sur-

faces of the two parts contact each other. See Figure 6-

9. Install the sprocket nut until finger tight.

Lubricate

Obtain FINAL DRIVE SPROCKET LOCKING TOOL

f1172a6x

Contact Surfaces

(HD-41184) to lock transmission sprocket. See Figure 6-

10. Proceed as follows:

Main Drive Gear

Transmission Sprocket

a. Insert handle of tool below pivot shaft inboard of

Large Oil Seal

Sprocket Nut

bottom frame tube and attach to sprocket. See

Quad Seal

Lockplate

upper frame of Figure 6-11.

Spacer

Socket Screw (2)

b. Snug thumbscrew to lock position of tool on

Figure 6-9. Install Transmission Sprocket Components

sprocket. See lower frame of Figure 6-11.

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a. Install pilot on threaded end of mainshaft. See

upper frame of Figure 6-13.

b. Slide sleeve of locknut wrench over pilot and onto

sprocket nut.

c. Tighten sprocket nut to 60 ft-lbs (81 Nm). See lower

frame of Figure 6-13. As the nut is tightened the

handle of the sprocket locking tool rises to contact

the pivot shaft, thereby preventing sprocket/main-

shaft rotation.

Figure 6-10. Final Drive Sprocket Locking Tool

(Part No. HD-41184)

Scribe a straight line on the transmission sprocket nut

continuing the line over onto the transmission sprocket

as shown in Figure

6-14. Tighten the transmission

sprocket nut an additional 35° to 40°.

Install lockplate over nut so that two diagonally opposite

holes align with two tapped holes in sprocket. To find the

best fit, lockplate can be rotated to a number of positions

and can be placed with either side facing sprocket.

If holes in lockplate do not align with those in sprocket,

tighten sprocket nut as necessary (up to the 45° maxi-

mum) until sprocket and lockplate holes are in align-

ment. See Figure 6-14.

CAUTION

Maximum allowable tightening of sprocket nut is 45° of

counterclockwise rotation after a torque of 60 ft-lbs (81

Nm). Do not loosen sprocket nut to align holes or nut will

f1855x7x

be under tightened.

Insert two socket head screws through lockplate into

f1856x7x

sprocket holes. Tighten screws to 84-108 in-lbs (9.5-

12.2 Nm).

NOTE

The socket head screws have a thread locking compound

that allows them to be reused up to three times. The fourth

time the screws are removed, replace with new screws (H-D

Part No. 3594).

Install primary chaincase assembly. See Section

6.5

PRIMARY CHAINCASE, INSTALLATION.

10. Install rear wheel and adjust belt deflection. See Section

2.4 REAR WHEEL, INSTALLATION.

REAR WHEEL SPROCKET

Transmission Sprocket

Pivot Shaft

Sprocket Locking Tool

Thumbscrew

REMOVAL

Figure 6-11. Install Final Drive Sprocket Locking Tool

Remove rear wheel. See Section 2.4 REAR WHEEL,

REMOVAL.

Obtain MAINSHAFT LOCKNUT WRENCH/PILOT (HD-

Remove five bolts with flat washers securing sprocket to

94660-37B). See Figure 6-12. Proceed as follows:

hub.

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f1977x6x

Wrench

Sprocket Nut

Pilot

45°

Figure 6-12. Mainshaft Locknut Wrench/Pilot

35°

(Part No. HD-94660-37B )

Scribe Line

on Nut and Sprocket

Figure 6-14. Tighten/Secure Sprocket Nut

Carefully inspect the sprocket for cracks or other dam-

age.

Inspect each sprocket tooth for large chrome chips hav-

ing sharp edges. Look for gouges caused by contact

with a hard object. If large enough, both of these condi-

tions will leave a corresponding pattern in the belt face

and are cause for rear sprocket replacement.

f1857x7x

Without obvious damage, rear wheel sprocket replace-

f1858x7x

ment may be a subjective decision based on general

appearance. Using medium pressure, drag a scribe or

the sharp point of a knife blade across the root of a

groove. Even though the plating is lightest in the root

area, a knife point should not penetrate the chrome. If

the blade slides across the chrome plating without dig-

ging in, then the chrome is still good. On the other hand,

if you can feel the scribe digging in and it leaves a visible

mark, then the chrome plating has worn off and the bare

aluminum is being cut. Loss of chrome is cause for rear

sprocket replacement.

INSTALLATION

Apply two drops of Loctite High Strength Threadlocker

Sprocket Nut

Mainshaft Locknut Wrench

271 (red) to threads of each of five sprocket bolts.

Pilot

Torque Wrench

Secure sprocket to hub using bolts with flat washers

(and locknuts on laced wheels). Tighten bolts to

Figure 6-13. Install Mainshaft Locknut Pilot/Wrench

55-65 ft-lbs (75-88 Nm).

and Torque Sprocket Nut

Install rear wheel and adjust belt deflection. See Section

2.4 REAR WHEEL, INSTALLATION.

CLEANING AND INSPECTION

Using a non-volatile cleaning solvent, thoroughly clean

the rear wheel sprocket of all grease and dirt.

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PRIMARY CHAINCASE

6.5

GENERAL

The primary chaincase is a sealed housing containing the

primary chain, clutch, engine compensating sprocket, chain

tensioner assembly, alternator and starter drive mechanism.

LUBRICATION

See Section 1.7 PRIMARY CHAIN/LUBRICANT, PRIMARY

CHAIN LUBRICANT.

REMOVAL

Remove seat. See Section 2.25 SEAT, REMOVAL.

1WARNING

To protect against shock and accidental start-up of vehi-

cle, disconnect the negative battery cable before pro-

ceeding. Inadequate safety precautions could result in

death or serious injury.

f1509b6x

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

Retaining Ring

Locknut

Standing on left side of motorcycle, remove magnetic

Release Plate

Adjuster Screw

drain plug at bottom of primary chaincase cover. Drain

lubricant into suitable container.

Figure 6-16. Clutch Hub Release Plate Assembly

NOTE

f1840x6x

If drain plug has accumulated a lot of debris, inspect the con-

dition of chaincase components.

Remove socket screw with lockwasher to remove pas-

senger footboard from rear swingarm bracket.

Remove socket screw (with lockwasher and flat washer)

to release front footboard forward bracket from frame

weldment. For best results, approach from opposite side

using a 3/8 inch ball allen with extension. To free front

footboard rear bracket from frame weldment and jiffy

stand bracket, remove lower hex bolt (with lockwasher)

and upper hex bolt (with lockwasher and locknut).

Remove locknut, lockwasher and flat washer to free shift

rod from inner shift arm.

Remove socket head screws and pull both heel and toe

shift levers from shift lever shaft. Remove rubber spacer.

Top Center Nut

If preferable, remove socket head screw to release inner

shift arm instead, and then pull shift lever shaft and heel-

Primary Chain

Adjuster Shoe

toe shift lever assembly from primary chaincase bore.

When pulling any lever from splined shaft, always mark

Figure 6-15. Primary Chain Tensioner Assembly

splines on both shaft and lever to assist in assembly.

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Remove ten allen head socket screws (with captive

f2389x6x

washers) from primary chaincase cover. Remove pri-

mary chaincase cover from motorcycle.

Loosen top center nut from captured bolt of chain ten-

sioner assembly. See Figure 6-15. Lower the chain ten-

sioner assembly as required, so that the adjuster shoe

rests flat on casting of primary chaincase.

1WARNING

Always wear proper eye protection when removing re-

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

Engine Compensating Sprocket Nut

worn. Slippage may propel the ring with enough force to

Sprocket Cover

cause eye injury.

Sliding Cam

Engine Compensating Sprocket

10. Remove retaining ring and pull release plate (with lock-

Shaft Extension

nut and adjuster screw) from clutch hub. See Figure 6-

16.

Figure 6-19. Engine Compensating Sprocket Assembly

11. See Figure 6-17. Obtain the PRIMARY DRIVE LOCK-

ING TOOL (HD-41214) and proceed as follows:

CAUTION

Do not place the tool on the lower strand of the primary

chain. Rotation of either the engine compensating

sprocket nut or clutch hub mainshaft nut causes tool to

exert enough force to break or shatter the nylon adjuster

shoe.

With the flat side against the upper strand of the primary

chain, insert stepped side of tool into teeth of engine

compensating sprocket. Using a breaker bar and 1-1/2

inch socket, turn the sprocket nut in a counterclockwise

Figure 6-17. Primary Drive Locking Tool

direction. Once the stepped area of the tool is drawn into

(Part No. HD-41214)

7859

7856

Primary Drive

Locking Tool

Primary Drive

Locking Tool

Breaker

Bar

Figure 6-18. Place Primary Drive Locking Tool

Figure 6-20. Place Primary Drive Locking Tool

and Loosen Engine Compensating Sprocket Nut

and Loosen Clutch Hub Mainshaft Nut

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14. Remove sprocket cover and sliding cam. See Figure 6-

Engine

7943

19.

Compensating

Sprocket

15. Remove clutch, primary chain, compensating sprocket

and shaft extension as a single assembly. See Figure 6-

21.

16. Bend tab on lockplate away from head of jackshaft bolt.

Holding pinion gear to prevent rotation, remove the jack-

Primary

shaft bolt with lockplate and thrust washer. Carefully pull

Chain

jackshaft assembly from primary chaincase bore.

17. From right side of motorcycle, remove starter front

mounting screw with lockwasher. Remove rear mounting

Shaft

screw with lockwasher, but do not disconnect chassis

Extension

Clutch

ground cable ring terminal.

Assembly

18. Returning to left side of motorcycle, remove two bolts

Figure 6-21. Remove Clutch Assembly, Primary Chain,

(with captive washers) from outside edge of primary

Engine Compensating Sprocket and Shaft Extension

chaincase.

19. Remove five inside bolts (with captive washers) to free

primary chaincase from crankcase and transmission

the sprocket, rotation of the primary drive is stopped.

housings. Remove primary chaincase from motorcycle.

Continue turning compensating sprocket nut until loose.

See Figure 6-18.

20. Remove O-ring from crankcase lip and discard.

NOTE

If too much loctite, or perhaps the wrong loctite, was used to

install the engine compensating sprocket nut, it may be very

difficult to remove. In these cases, break down loctite using

INSPECTION AND REPAIR

heat from a small propane torch. Apply heat evenly around

nut head in a circular motion, but not for so long as to turn nut

blue. Do not direct heat at chain tensioner assembly and

Inspect the primary chaincase for cracks or other dam-

other components or damage will result. If unable to loosen

age. Replace as necessary.

sprocket nut with breaker bar after applying heat, use air

impact wrench as the last alternative.

Check the mainshaft bearing. Bearing must rotate freely

without drag. Replace the bearing if necessary. Replace

the lip seal. See MAINSHAFT BEARING AND LIP SEAL

1WARNING

on this page.

NOTE

Use extreme caution when operating propane torch.

Read the manufacturers instructions carefully before

Also check the bearing inner race on the mainshaft. Replace

use. Do not direct open flame or heat toward any fuel

the race if scored or excessively worn. See MAINSHAFT

system component. Extreme heat can cause fuel ignition

BEARING INNER RACE in this section.

and explosion. Inadequate safety precautions could

result in death or serious injury.

Check the starter jackshaft bushing in the primary chain-

case. Check the jackshaft bushing in the primary chain-

12. Reverse the position of the primary drive locking tool.

case cover. Replace the bushings if they are damaged

With the flat side against the upper strand of the primary

or excessively worn (i.e., through the teflon and copper

chain, insert stepped side of tool into teeth of clutch

coatings into the steel backing). Replace the lip seal.

sprocket. Using a breaker bar and 1-3/16 inch socket,

See STARTER JACKSHAFT LIP SEAL AND BUSHING

turn the clutch hub mainshaft nut in a clockwise direction

- PRIMARY CHAINCASE in this section.

until loose. See Figure 6-20.

Check the shifter bushings in the primary chaincase.

NOTE

Replace the bushings if necessary. See SHIFTER

BUSHINGS in this section.

Clutch hub mainshaft nut has left handed threads.

13. Remove the primary drive locking tool. Remove the

clutch hub mainshaft nut and engine compensating

sprocket nut.

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DISASSEMBLY

f1216x6x

MAINSHAFT BEARING AND LIP SEAL

REMOVAL

1WARNING

Always wear proper eye protection when removing re-

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

cause eye injury.

Figure 6-22. Mainshaft Bearing Inner Race Remover

(Part No. HD-34902B)

Remove retaining ring from groove on clutch side of pri-

mary chaincase. Turn the chaincase over to transmis-

sion side.

f1217x7x

Pull lip seal from bearing bore on transmission side of

primary chaincase. Use a seal remover or rolling head

pry bar for best results. Remove retaining ring from

groove on same side of chaincase.

Bearing

Inner Race

CAUTION

Mainshaft

Failure to provide proper support will cause the casting

Plug

to crack or break around the outside diameter of the

boss. Any damage to the casting requires replacement

Bridge

of the primary chaincase.

Place primary chaincase in arbor press with the trans-

mission side up. Be sure to properly support boss on

clutch side to avoid damage to casting.

Center bearing under ram, and using a suitable driver,

Puller

Long

carefully press out bearing applying pressure to the

Plate

Bolt

Flat

outer race.

Washer

Forcing

INSTALLATION

Screw

Inspect the bearing bore to verify that it is clean and

Figure 6-23. Pull Mainshaft Bearing Inner Race

smooth.

CAUTION

1WARNING

Failure to provide proper support will cause the casting

Always wear proper eye protection when installing re-

to crack or break around the outside diameter of the

taining rings. Use the correct retaining ring pliers. Verify

boss. Any damage to the casting requires replacement

that the tips of the pliers are not damaged or excessively

of the primary chaincase.

worn. Slippage may propel the ring with enough force to

cause eye injury.

Place primary chaincase in arbor press with the clutch

side up. Be sure to properly support boss on transmis-

Install retaining ring in groove on transmission side of

sion side to avoid damage to casting.

primary chaincase. Verify that the retaining ring is fully

seated in the groove.

Place bearing over bore with the lettered side up. Center

bearing under ram, and using a suitable driver, apply

Apply a thin film of clean H-D 20W50 engine oil to bear-

pressure to the outer race until bearing makes contact

ing bore and O.D. of new bearing.

with the installed retaining ring.

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Install second retaining ring to lock position of bearing in

bore on clutch side of chaincase. Verify that retaining

f1215x6x

ring is fully seated in the groove.

Turn chaincase over, so that the transmission side is up.

Lubricate O.D. of new lip seal with clean H-D 20W50

engine oil. With the lip garter spring side (also stamped

“OIL SIDE”) facing the bearing, press lip seal into bore

until outer edge is flush with machined surface of the

casting. To avoid seal damage, be sure to use a suitable

driver that presses squarely on the outer edge of the

seal carrier.

Verify that lip seal is square in the bore and completely

Figure 6-24. Mainshaft Bearing Inner Race Installer

seated around its circumference.

(Part No. HD-34902B)

10. Lubricate the bearing and lip seal with multi-purpose

grease or clean H-D 20W50 engine oil.

Install Inner Race

and Extension Shaft

MAINSHAFT BEARING INNER RACE

NOTE

The bearing inner race must be properly positioned on the

mainshaft to align with the bearing outer race in the primary

Extension

chaincase. To remove and install the bearing inner race, use

Shaft

the combination MAINSHAFT BEARING INNER RACE

REMOVER/INSTALLER, Part No. HD-34902B. See Figure 6-

22 and Figure 6-24.

Wrench

REMOVAL

Flat

Install small flat washers on two long bolts of puller tool.

Slide one bolt into channel on each side of bridge so that

washer is between bridge and bolt head. Thread bolts

Bearing

into stamped side of U-shaped puller plate an equal

Inner Race

number of turns.

Sparingly apply graphite lubricant to threads of forcing

screw to ensure smooth operation. Thread forcing screw

into center hole of bridge.

Install Tube, Flat Washers

Position U-shaped puller plate between bearing inner

and Hex Nut

race and sprocket nut. See Figure 6-23.

Install mainshaft plug into end of transmission main-

shaft. Thread the forcing screw into the bridge until the

steel ball at the end of the screw seats in the cavity of

the mainshaft plug. Verify that the tool assembly is

square so that the bearing is not cocked during removal.

Continue turning the forcing screw until the bearing inner

Flat

race is pulled free of the mainshaft.

Washers

INSTALLATION

Chamfered edge first, slide the bearing inner race onto

the transmission mainshaft.

Thread extension shaft onto end of mainshaft. See

Installer

upper frame of Figure 6-25.

Tube

Hex

f1218x7x

NOTE

Nut

Extension shaft has left handed threads, so turn counter-

clockwise to install.

Figure 6-25. Press Bearing Inner Race onto Mainshaft

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Slide installer tube over extension shaft until it contacts

bearing inner race. Sparingly apply graphite lubricant to

9474

threads of extension shaft to ensure smooth operation.

Place both large flat washers over threaded portion of

extension shaft until they contact installer tube. Install

large hex nut onto extension shaft. See lower frame of

Figure 6-25.

With a wrench on flats at threaded end of extension

shaft, hold shaft stationary while turning hex nut in a

clockwise direction. In this manner, press race onto shaft

so inside edge is 0.100 in. (2.54 mm) from main drive

gear.

Lubricate the race with multi-purpose grease or clean

Figure 6-26. Install Jackshaft Lip Seal with Open Side

engine oil.

of Seal Carrier on the Clutch Side

STARTER JACKSHAFT LIP SEAL AND

INSTALLATION

BUSHING - PRIMARY CHAINCASE

Remove five T27 TORX screws (with captive washers) to

REMOVAL

free clutch inspection cover from primary chaincase

Remove lip seal and bushing from jackshaft bore of pri-

cover.

mary chaincase. Approach from the transmission side

Place primary chaincase cover in arbor press. Support

using a suitable seal or bushing driver.

forward part of case so that it lies flat around the clutch

Inspect the jackshaft bore to verify that it is clean and

inspection cover bore.

smooth.

Press new bushing into bore using a suitable bushing

driver. Bushing must be flush with boss or at a depth not

INSTALLATION

exceeding 0.010 in. (0.25 mm).

Place primary chaincase in arbor press with the clutch

side up. Support forward part of case so that it lies flat

Lubricate the bushing with clean engine oil.

on transmission mounting flanges.

Lightly apply clean engine oil to O.D. of new lip seal.

With the open side of the seal carrier facing up, place lip

SHIFTER BUSHINGS

seal in the jackshaft bore. See Figure 6-26.

REMOVAL

Using a suitable seal or bushing driver, press squarely

on the outer edge of the seal carrier until it makes solid

Using an arbor press, press bushings from bore. Inspect

contact with the shoulder on the transmission side.

the bushing bore to verify that it is clean and smooth.

Verify that seal is square in the bore and completely

seated around its circumference.

Press new bushing into bore. Bushing must be flush with

INSTALLATION

boss or at a depth not exceeding 0.010 in. (0.25 mm).

Place primary chaincase in arbor press.

Lubricate the bushing and lip seal with clean engine oil.

Press new bushing into each end of bore. Installed

bushings must be flush to 0.010 inch (0.76 mm) above

outer edge of bore.

STARTER JACKSHAFT BUSHING -

PRIMARY CHAINCASE COVER

Assemble primary chaincase. See Section

6.5 PRI-

MARY CHAINCASE, INSTALLATION, on the next page.

REMOVAL

Remove bushing from jackshaft bore of primary chain-

case cover. For best results, use a suitable bushing/

bearing puller.

Inspect the bushing bore to verify that it is clean and

smooth.

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f2372x6x

7,8

Clutch inspection cover

Gasket

Screw (5)

Primary chain inspection cover

Gasket

Screw (4)

13. Primary chaincase

Magnetic drain plug

14. O-ring

O-ring

15. Dowel pin (2)

20. Jackshaft case bushing

Primary chaincase cover

16. Bolt (3), 5/16-18 x 3 in.

21. Jackshaft cover bushing

10. Gasket

17. Bolt (4), 5/16-18 x 1-3/4 in.

22. Lip seal

11. Screw (5), 1/4-20 x 1-1/2 in.

18. Bushing (2)

23. Retaining ring (2)

12. Screw (5), 1/4-20 x 1-1/4 in.

19. Jackshaft lip seal

24. Mainshaft bearing

Figure 6-27. Primary Chaincase Assembly

INSTALLATION

CAUTION

Install new O-ring on lip of crankcase.

The presence of sealant, residual loctite, dirt, water or oil

in the blind holes of the crankcase or transmission can

CAUTION

cause the castings to crack or break.

Avoid the use of sealant where the primary chaincase

Verify cleanliness of all blind holes in both the crankcase

mates with the crankcase/transmission interface. Use of

and transmission.

sealant can interfere with the mating of these parts.

NOTE

CAUTION

If the use of sealant is absolutely necessary to eliminate oil

wicking past the primary chaincase bolts, use only a light film

The mainshaft splines may damage the sealing surface

around the bolt holes on the mating surfaces. With one

of the lip seal if the protector sleeve is not used.

exception, remember that all bolts go into blind holes. The

only open hole is located at the bottom of the transmission

Place the seal protector sleeve (from the MAIN DRIVE

case. See right frame of Figure 6-28.

GEAR SEAL INSTALLER, HD-41405) over the main-

shaft splines. Lightly lubricate the sleeve with clean

Verify that the mating surfaces of the primary chaincase

engine oil.

and crankcase/transmission interface are clean.

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Start four 1-3/4 inch bolts to engine.

Start three 3 inch bolts to transmission.

9361

Only Open Hole

9362

Figure 6-28. Primary Chaincase Screw Size and Torque Sequence

Place the primary chaincase into position against the

Returning to left side of motorcycle, gently insert jack-

crankcase and transmission housings. Remove the seal

shaft assembly into primary chaincase so that splined

protector sleeve from the mainshaft.

end of shaft engages coupling on starter output shaft.

Install primary chaincase bolts as follows:

Insert key on lockplate through slot in thrust washer and

into keyway on jackshaft. Thread the jackshaft bolt into

NOTE

the starter shaft making sure that the lockplate key

remains in the keyway. Holding pinion gear to prevent

Wherever the primary chaincase bolts are to be resused,

rotation, tighten jackshaft bolt to 60-80 in-lbs (6.8-9.0

clean threads and apply two drops of Loctite Medium

Strength Threadlocker 243 (blue) before installation.

Nm). Bend tab on lockplate against flat of bolt head to

secure.

a. See A in left frame of Figure 6-28. Start two bolts (1-

3/4 inches with captive washers) to fasten outside

Install the clutch, primary chain, compensating sprocket

edge of primary chaincase to front of crankcase.

and shaft extension as a single assembly. See Figure 6-

21. Start clutch assembly on the mainshaft, while plac-

b. See B in left frame of Figure 6-28. From within the

primary chaincase, start two bolts (1-3/4 inches with

ing the shaft extension on the engine sprocket shaft. The

captive washers) to fasten primary chaincase to

clutch hub and shaft extension are splined, so a slight

rear of crankcase.

rotation of the chain drive will aid in lining up the splines.

c. See right frame of Figure 6-28. From within the pri-

10. Place sliding cam over shaft extension. Slide sprocket

mary chaincase, start three bolts (3 inches with

cover over sliding cam. See Figure 6-19.

captive washers) to fasten primary chaincase to

front and rear of transmission.

11. Install the engine compensating sprocket nut. The fol-

d. Tighten the seven bolts to 15-19 ft-lbs (20.3-25.8

lowing procedure is based on whether a new or used nut

Nm) in the numerical sequence shown in Figure 6-

is being installed.

28.

On right side of motorcycle, install the front starter

CAUTION

mounting screw with lockwasher. Install rear mounting

Exercise caution to avoid getting oil on the threads of

screw and lockwasher (with chassis ground cable ring

the sprocket nut or the integrity of the lock patch (new

terminal). Alternately tighten front and rear starter

nut) or Loctite (used nut) may be compromised.

mounting screws to 14-18 ft-lbs (19-24 Nm).

6-22

2006 Touring: Drive

HOME

New sprocket nut: smear a small quantity of clean

engine oil on the inside face of the sprocket nut and the

CAUTION

outside face of the sprocket cover. Limit the application

to where the surfaces of the two parts contact each

Do not place the tool on the lower strand of the primary

chain. Rotation of either the engine compensating

other. Install nut and hand tighten in a clockwise direc-

sprocket nut or clutch hub mainshaft nut causes tool to

tion.

exert enough force to break or shatter the nylon adjuster

Used sprocket nut: apply two drops of Loctite High

shoe.

Strength Threadlocker 262 (red) to the threads of the

a. With the flat side against the upper strand of the pri-

engine compensating sprocket nut. Also smear a small

quantity of clean engine oil on the inside face of the

mary chain, insert stepped side of tool into teeth of

sprocket nut and the outside face of the sprocket cover.

clutch sprocket. Verify that adjuster shoe of chain

Limit the application to where the surfaces of the two

tensioner assembly rests flat on casting of primary

parts contact each other. Install nut and hand tighten in

chaincase, and then using torque wrench and 1-1/2

a clockwise direction.

inch socket, tighten engine compensating sprocket

nut to 75 ft-lbs (101.7 Nm). See Figure 6-30.

12.

Apply two drops of Loctite High Strength Threadlocker

262 (red) to the threads of the clutch hub mainshaft nut.

NOTE

Install nut and hand tighten in a counterclockwise

Once the stepped area of the tool is drawn into the sprocket,

direction.

rotation of the primary drive is stopped.

NOTE

b. Mark a straight line on the engine compensating

Clutch hub mainshaft nut has left handed threads.

sprocket nut continuing the line over onto the

sprocket cover. Tighten the engine compensating

13.

See Figure 6-29. Obtain the PRIMARY DRIVE LOCK-

sprocket nut an additional 45° to 50°.

ING TOOL (HD-41214) and proceed as follows:

14. Reverse the position of the primary drive locking tool.

With the flat side against the upper strand of the primary

chain, insert stepped side of tool into teeth of engine

compensating sprocket. Using torque wrench and 1-3/16

inch socket, tighten clutch hub mainshaft nut to 70-80 ft-

lbs (95-108 Nm). See Figure 6-31.

15. Remove the primary drive locking tool.

16. Install release plate (with locknut and adjuster screw)

into clutch hub bore. The word “OUT” is stamped on the

release plate to indicate the outboard side.

Figure 6-29. Primary Drive Locking Tool

(Part No. HD-41214)

Primary Drive

Locking Tool

Torque

Wrench

7857

7858

Figure 6-30. Place Primary Drive Locking Tool

Figure 6-31. Place Primary Drive Locking Tool

and Torque Engine Compensating Sprocket Nut

and Torque Clutch Hub Mainshaft Nut

2006 Touring: Drive

6-23

HOME

17. Install retaining ring in clutch hub bore to lock release

S = Short Screw, 1-1/4 In.

f1210x6x

plate in position. Verify that the retaining ring is com-

L = Long Screw, 1-1/2 In.

pletely seated in the groove.

18. Adjust clutch. See Section 1.8 CLUTCH ADJUSTMENT,

steps 3-8.

19. Adjust primary chain tension. See Section 1.7 PRIMARY

CHAIN/LUBRICANT, PRIMARY CHAIN ADJUST-

MENT, steps 4-6.

20. Remove old gasket from flange of primary chaincase

and discard. Thoroughly clean gasket surface. Hang

new gasket on dowels.

Clutch

Inspection

Primary

Cover

21. Start ten allen head socket screws (five long, five short)

Chain

with flat washers to install primary chaincase cover.

Inspection

Cover

Tighten screws to

84-108 in-lbs (10-12 Nm) in the

numerical sequence shown in Figure 6-32.

22. Clean magnetic drain plug and inspect O-ring for cuts,

tears or signs of deterioration. Replace O-ring as neces-

Drain

sary. Install drain plug back into primary chaincase cover

Plug

and tighten to 36-60 in-lbs (4.1-6.8 Nm).

23. Remove five T27 TORX screws (with captive washers) to

free clutch inspection cover from primary chaincase

Figure 6-32. Primary Chaincase Cover Torque Sequence

cover, if installed.

and Screw Size

CAUTION

Do not overfill the primary chaincase with lubricant.

Overfilling may cause rough clutch engagement, incom-

plete disengagement, clutch drag and/or difficulty in

finding neutral at engine idle.

1WARNING

Be sure that lubricant does not contact rear wheel, tire

and brake components. Such contact can adversely

affect traction and may lead to loss of vehicle control,

which could result in death or serious injury.

24. Pour

32 ounces (946 ml) of Harley-Davidson FOR-

MULA+ TRANSMISSION AND PRIMARY CHAINCASE

LUBRICANT through the clutch inspection cover open-

ing, Part No. 99851-05 (quart). See Figure 6-33.

25. To avoid punching holes in the clutch inspection cover

gasket or enlarging existing holes, install clutch inspec-

tion cover and new gasket as follows:

f2301x6x

a. Align the triangular shaped hole in the gasket with

the top hole in the clutch inspection cover. Be sure

Figure 6-33. Add Primary Chaincase Lubricant

the rubber molding and the words “towards clutch”

face the motorcycle.

b. Insert screw (with captive washer) through clutch

1WARNING

inspection cover and carefully thread it all the way

through triangular shaped hole in gasket. Do not

Always wear proper eye protection when installing re-

push screw through hole.

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

c. Hang the clutch inspection cover on the primary

worn. Slippage may propel the ring with enough force to

chaincase cover flange by starting the top cover

cause eye injury.

screw.

6-24

2006 Touring: Drive

HOME

28.

Install socket screw with lockwasher to fasten passenger

footboard to rear swingarm bracket. Tighten screw to 15-

f1210x6x

18 ft-lbs (20-24 Nm). Repeat step on opposite side of

motorcycle.

29.

Install left side footboard and bracket assembly as fol-

lows:

a. Insert socket screw

(with lockwasher and flat

washer) through frame weldment into front foot-

board forward bracket. For best results, approach

from opposite side of motorcycle using a 3/8 inch

ball allen with extension.

b. At front footboard rear bracket, slide upper hex bolt

through frame weldment, jiffy stand bracket and

footboard bracket thru hole. Install lockwasher and

locknut. Slide lower hex bolt through frame weld-

ment and jiffy stand bracket into threaded hole of

footboard bracket.

Figure 6-34. Clutch Inspection Cover Torque Sequence

c. Tighten front bracket socket screw to 30-35 ft-lbs

(41-48 Nm).

d. Alternately tighten rear bracket hex bolts to 15-20 ft-

d. Start the remaining four screws (with captive wash-

lbs (20-27 Nm).

ers).

e. Using a T27 TORX drive head, alternately tighten

30.

Insert bolt through battery negative cable (black) into

screws to 84-108 in-lbs (10-12 Nm) in the pattern

threaded hole of battery negative (-) terminal. Tighten

shown in Figure 6-34.

bolt to 60-96 in-lbs (6.8-10.9 Nm).

31.

Install seat. See Section 2.25 SEAT, INSTALLATION.

26.

If installing heel-toe shift levers onto shift lever shaft, per-

form steps 26(a) thru 26(d). If just installing inner shift

arm onto shift lever shaft, perform steps 26(d) thru 26(f).

a. Set the heel-toe shift levers down, so that the Har-

ley-Davidson script on the rubber peg is topside.

Now look at the socket head screw hole. If the hole

is countersunk at the bottom, then it is the inboard

shift lever (toe). If the hole is countersunk at the top,

it is the outboard shift lever (heel).

b. Install heel-toe shift levers onto splines of shift lever

shaft taking note to align marks placed on splines

during disassembly.

c. Install socket head screws to fasten heel-toe shift

levers to shift lever shaft. Tighten 5/16 inch screws

to 18-22 ft-lbs (24-30 Nm).

d. Install rubber spacer onto shift lever shaft. Install

shift lever shaft into primary chaincase bore.

e. Install inner shift arm onto splines of shift lever shaft

taking note to align marks placed on splines during

disassembly.

Install socket head screw to fasten inner shift arm to

shift lever shaft. Tighten 1/4 inch screw to 90-110

in-lbs (10.2-12.4 Nm)

27.

Install flat washer, lockwasher and locknut to fasten shift

rod to inner shift arm.

2006 Touring: Drive

6-25

HOME

SPECIFICATIONS

7.1

TRANSMISSION DATA

SERVICE WEAR LIMITS

TRANSMISSION

DATA

SHIFTER FORKS

IN.

5-speed forward -

Shifter fork to cam

Type

0.0017-0.0019

0.043-0.048

constant mesh

groove end play

FORMULA+ TRANSMISSION

Shifter fork to gear

0.0010-0.0110

0.025-0.279

AND PRIMARY CHAINCASE

Part No. 99851-05 (qt)

groove end play

LUBRICANT

24 oz.

Capacity (dry)

710 ml

SHIFTER DOG

MINIMUM

MAXIMUM

GEARS

CLEARANCE

Approximately

20-24 oz.

0.035 in.

0.139 in.

Capacity (wet)

2nd-5th

590-710 ml

0.89 mm

3.53 mm

0.035 in.

0.164 in.

2nd-3rd

0.89 mm

4.17 mm

Internal Gear Ratios

0.035 in.

0.152 in.

GEAR

(Domestic, HDI and Swiss)

1st-4th

0.89 mm

3.86 mm

First

3.21

0.035 in.

0.157 in.

1st-3rd

Second

2.21

0.89 mm

3.99 mm

Third

1.57

Fourth

1.23

MAINSHAFT

Fifth

1.00

IN.

TOLERANCE

Mainshaft runout

0.000-0.003

0.000-0.08

ENGINE OIL

DATA

Mainshaft end play

none

1st gear clearance

0.0000-0.0080

0.000-0.203

4 quarts

Capacity (dry)

2nd gear clearance

0.0000-0.0800

0.000-2.032

3.8 liters

3rd gear end play

0.0050-0.0420

0.127-1.067

Approximately

Capacity (wet)

3-1/2 quarts

3rd gear clearance

0.0003-0.0019

0.008-0.048

3.3 liters

4th gear end play

0.0050-0.0310

0.127-0.787

4th gear clearance

0.0003-0.0019

0.008-0.048

CAUTION

A bent jiffy stand, modified suspension or uneven park-

MAIN DRIVE

IN.

ing area can cause dipstick to indicate a false low oil

GEAR (5TH)

condition.

Bearing fit in

NOTE

transmission case

0.0003-0.0017

0.008-0.043

(loose)

Since a sidecar equipped motorcycle is fixed in an upright

position, the actual full engine oil level is about 1/2 inch (12.7

Fit on mainshaft

0.0001-0.0009

0.0025-0.023

mm) above the FULL mark on the dipstick.

End play

none

Fit in side door (tight)

0.0014-0.0001

0.036-0.0025

2006 Touring: Transmission

7-1

HOME

SERVICE WEAR LIMITS (CONT.’D)

TORQUE VALUES

COUNTERSHAFT

IN.

TOLERANCE

Item

ft/in-lbs

Countershaft runout

0.000-0.003

0.00-0.08

Shifter linkage rod

80-120 in-lbs

9.0-13.6 Nm

locknuts

Countershaft end play

none

Detent arm pivot screw

1st gear clearance

0.0003-0.0019

0.008-0.048

84-108 in-lbs

9.5-12.2 Nm

to right support block

1st gear end play

0.0050-0.0039

0.127-0.099

Shifter cam support

84-108 in-lbs

9-12 Nm

block screws

2nd gear clearance

0.0003-0.0019

0.008-0.048

Transmission top cover

84-132 in-lbs

9.5-14.9 Nm

2nd gear end play

0.0050-0.0440

0.127-1.118

socket head screws

3rd gear clearance

0.0000-0.0080

0.000-0.203

Neutral switch

120-180 in-lbs

13.6-20.3 Nm

Clutch release cover

4th gear clearance

0.0000-0.0080

0.000-0.203

84-132 in-lbs

9.5-14.9 Nm

socket head screws

4th gear end play

0.0050-0.0390

0.127-0.991

Clutch cable fitting

36-60 in-lbs

4-7 Nm

5th gear clearance

0.0000-0.0080

0.000-0.203

Transmission lubricant

14-21 ft-lbs

19-28 Nm

drain plug

5th gear end play

0.0050-0.0040

0.127-0.102

Transmission filler

25-75 in-lbs

2.8-8.5 Nm

plug/dipstick

Transmission side door

5/16 inch screws

13-18 ft-lbs

17.6-24.4 Nm

1/4 inch screws

84-132 in-lbs

9.5-14.9 Nm

Mainshaft/countershaft

45-55 ft-lbs

61-75 Nm

locknuts

Transmission mainshaft

60 ft-lbs, then

81 Nm, then

sprocket nut

35° to 45°

Transmission sprocket

84-108 in-lbs

9-12 Nm

nut lockplate screws

Oil pan screws

84-132 in-lbs

9.5-14.9 Nm

15 ft-lbs,

20.3 Nm,

Transmission-to-engine

then

mounting bolts

30-35 ft-lbs

40.7-47.5 Nm

Oil hose cover

84-108 in-lbs

10-12 Nm

Rear swingarm

34-42 ft-lbs

46-57 Nm

bracket bolts

Rear swingarm

40-45 ft-lbs

54-61 Nm

pivot shaft locknut

Shifter lever to shifter shaft

18-22 ft-lbs

24-30 Nm

socket head screw

Engine oil drain plug

14-21 ft-lbs

19-28 Nm

Oil filler spout allen head

84-132 in-lbs

9.5-14.9 Nm

socket screws

Shift arm to trans-

mission shift shaft

5/16”

18-22 ft-lbs

24-30 Nm

socket screw

Inner shift arm to

shift lever shaft

1/4”

90-110 in-lbs

10.2-12.4 Nm

socket screw

7-2

2006 Touring: Transmission

Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 20