Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 22
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MAIN DRIVE GEAR/BEARING
7.7
PRELIMINARY INSTRUCTIONS
4
5
6
7
8
NOTE
9
Leave the transmission case in the frame unless the case
3
itself requires replacement. For illustration purposes, some
photographs may show the case removed.
1.
Remove the exhaust system in two sections. See Sec-
tion 2.38 EXHAUST SYSTEM, REMOVAL.
2
1
2.
Remove the shifter cam and shifter fork assemblies. See
Section
7.4 SHIFTER CAM ASSEMBLY/SHIFTER
FORKS, DISASSEMBLY.
1.
Cross Plate
6.
Hex Nut
2.
12 Inch Bolt
7.
8 Inch Bolt
3.
Remove the primary chaincase cover. Remove the
3.
Driver
8.
Backing Plate
clutch assembly, primary chain, and compensating
4.
Nice Bearing
9.
Installer Cup
sprocket components. Remove the starter jackshaft
5.
Flat Washer
assembly and primary chaincase. See Section 6.5 PRI-
MARY CHAINCASE, REMOVAL.
Figure 7-28. Main Drive Gear/Bearing Remover/Installer
4.
Remove the starter. See Section
5.4 STARTER,
(Part No. HD-35316B)
REMOVAL, steps 6-11.
5.
Moving to rear wheel, remove E-clip and loosen hex nut
on right side of axle. Moving to left side, turn adjuster
7.
See Figure 7-27. Remove the six socket head screws
cam in a counterclockwise direction until belt tension is
(bottom four with flat washers) to free both the side door
relieved. Remove the belt from the transmission
and transmission exhaust bracket from the transmission
sprocket.
case. Pull the side door, mainshaft and countershaft
from the transmission case as a single assembly.
6.
Remove the bearing inner race from the transmission
Remove and discard the door gasket.
mainshaft. See Section
6.5 PRIMARY CHAINCASE,
MAINSHAFT BEARING INNER RACE, REMOVAL.
NOTE
DO NOT USE A HAMMER TO REMOVE THE SIDE DOOR.
If the side door sticks or binds on the locating dowels, gently
pry open using the indents at each side of the door. See Fig-
7970
ure 7-27. Exercise caution to avoid damaging paint.
8.
Remove the two socket screws and lockplate to free the
sprocket nut. Remove the sprocket nut. Use an air
impact wrench for best results.
NOTE
The transmission sprocket nut has left handed threads. Turn
the nut clockwise to remove from the main drive gear.
9.
Remove the transmission sprocket.
REMOVAL
1.
Obtain the MAIN DRIVE GEAR/BEARING REMOVER/
INSTALLER (HD-35316B). See Figure 7-28.
Side
Rear
Door
Indent
2.
Obtain two screws with flat washers not provided with
tool. One screw must be 1/4-20 x 1 inch, and the other
Figure 7-27. Remove Transmission Side Door
must be 5/16-18 x 1-1/2 inch.
2006 Touring: Transmission
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8.
Holding head of bolt on right side of transmission case,
9443
turn hex nut on left side in a clockwise direction until
main drive gear is free.
9.
Remove tool. Remove main drive gear from inside
transmission case.
10. On left side of transmission case, pull spacer from bore
of large oil seal.
11. Remove quad seal from either bevel on spacer or shoul-
der on main drive gear. Discard quad seal.
NOTE
Always replace the main drive gear bearing when the main
drive gear is removed. The bearing will be damaged during
the removal procedure.
Figure 7-29. Main Drive Gear Removal
(Right Side)
1WARNING
9444
Always wear proper eye protection when removing
retaining rings. Use the correct retaining ring pliers. Ver-
ify that the tips of the pliers are not damaged or exces-
sively worn. Slippage may propel the ring with enough
force to cause eye injury.
12. Remove retaining ring from groove in bearing bore.
13. From inside transmission case, use a block of wood and
rubber mallet to gently tap bearing (and large oil seal)
towards the outside. Discard bearing and large oil seal.
CLEANING AND INSPECTION
1.
Clean all parts in solvent except the transmission case
and needle bearings. Blow dry with compressed air.
Figure 7-30. Main Drive Gear Removal
(Left Side)
CAUTION
Do not clean the transmission case and needle bearings.
3.
With the stamp “this side out” facing outboard and the
Normal cleaning methods will wash dirt and other con-
script right side up, fasten cross plate to right side of
taminants into the bearing case and behind the needle
bearings leading to bearing failure.
transmission case using second most rearward set of
holes in the side door flange. Install the 1/4-20 x 1 inch
2.
Inspect the main drive gear for pitting and wear. Replace
screw (with flat washer) in the top flange hole, the 5/16-
if necessary.
18 x 1-1/2 inch screw (with flat washer) in the bottom
3.
Inspect the needle bearings inside the main drive gear.
flange hole. Alternately tighten screws until snug.
Replace the needle bearings if the mainshaft race is pit-
4.
Slide 12 inch bolt through center hole in cross plate until
ted or grooved.
threaded end exits left side of transmission case. See
4.
Replace the sprocket if teeth are cracked or worn. See
Figure 7-29.
Section 6.4 SECONDARY DRIVE BELT AND SPROCK-
ETS, TRANSMISSION SPROCKET, for more informa-
5.
On left side of transmission case, slide driver over end of
tion.
bolt with the side stamped “S” facing the transmission
case.
6.
Sparingly apply graphite lubricant to threads of bolt to
Needle Bearing Replacement
ensure smooth operation and prolong service life.
NOTE
7.
Install Nice bearing, flat washer and hex nut on bolt. See
If the main drive gear needle bearings and/or small oil seal
Figure 7-30.
need to be replaced, proceed as follows.
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2006 Touring: Transmission
HOME
8254
Needle
Ram
Bearing
Installer
Small
0.080 In. Step
Oil Seal
0.315 In. Step
Outer
Needle
Bearing
Main Drive
Gear
8252
Figure 7-32. Press Small Oil Seal into Main Drive Gear
Figure 7-31. Press Clutch Side Needle Bearing into
Main Drive Gear
8253
Inner
1.
Pull small oil seal from splined end of main drive gear.
Needle
Use a seal remover or rolling head pry bar for best
Bearing
results.
0.080 In. Step
2.
Remove needle bearings using a bushing/bearing puller
or a suitable straight-thru press tool.
3.
Obtain the MAIN DRIVE GEAR NEEDLE BEARING
AND SMALL OIL SEAL INSTALLER (HD-37842A).
4.
With the splined side up, center main drive gear under
ram of arbor press.
5.
Start new outer (clutch side) needle bearing into splined
end.
6.
Insert the 0.315 inch step end of tool into needle bear-
ing.
7.
Apply pressure until shoulder on tool makes light contact
Figure 7-33. Press Transmission Side Needle
with the gear. See Figure 7-31. Remove tool.
Bearing into Main Drive Gear
8.
Lightly apply Loctite RETAINING COMPOUND No. 609
to OD of new small oil seal.
9.
With the lip garter spring side down, start oil seal into
12.
Turn the main drive gear over so that the gear side is up.
splined end.
13.
Start new inner (transmission side) needle bearing into
10.
Turn the tool over and insert the 0.080 inch step end into
gear end.
oil seal.
11.
Apply pressure until shoulder on tool makes light contact
14.
Insert the 0.080 inch step end of tool into needle bear-
with the gear. See Figure 7-32. Remove tool.
ing.
NOTE
15.
Apply pressure until shoulder on tool makes light contact
An alternative method is provided which allows the small oil
with the gear. See Figure 7-33. Remove tool.
seal to be pressed into place after installation of the main
drive gear. For more information, see FINAL INSTRUC-
TIONS, step 14.
2006 Touring: Transmission
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9443
9446
Figure 7-34. Main Drive Gear Bearing Installation
Figure 7-36. Main Drive Gear Installation
(Right Side)
(Right Side)
9445
9447
Figure 7-35. Main Drive Gear Bearing Installation
Figure 7-37. Main Drive Gear Installation
(Left Side)
(Left Side)
3.
On left side of transmission case, slide new bearing over
INSTALLATION
end of bolt with the lettered side out.
4.
With the side stamped “S” facing the transmission case,
NOTE
slide driver over end of bolt until it contacts bearing.
A light interference fit should allow the main drive gear bear-
5.
Install Nice bearing, flat washer and hex nut on bolt. See
ing to be hand pressed into the transmission case. Move to
Figure 7-35.
step 7 if the bearing installs easily by hand. If the bearing is
difficult to install, start at step 1 below.
6.
Holding head of bolt on right side of transmission case,
turn hex nut on left side in a clockwise direction until
1.
If removed, fasten cross plate to right side of transmis-
bearing bottoms in the bore. Remove tool.
sion case using second most rearward set of holes in
the side door flange (with the stamp “this side out” facing
1WARNING
outboard and the script right side up). Alternately tighten
screws until snug.
Always wear proper eye protection when installing
retaining rings. Use the correct retaining ring pliers. Ver-
2.
Slide 12 inch bolt through center hole in cross plate until
ify that the tips of the pliers are not damaged or exces-
threaded end exits left side of transmission case. See
sively worn. Slippage may propel the ring with enough
Figure 7-34.
force to cause eye injury.
7-26
2006 Touring: Transmission
HOME
a. With the lip garter spring side out (toward the trans-
9448
mission case), place a new large oil seal on lip of
tool.
b. Lightly apply Loctite RETAINING COMPOUND No.
609 to OD of oil seal.
c. Slide tool over the main drive gear so that it is posi-
tioned squarely over the bearing bore.
d. Hand press the oil seal into the bore. If necessary,
use a rubber mallet to lightly tap the tool.
15. Carefully slide new quad seal down main drive gear until
it contacts shoulder.
16. Apply a small amount of clean transmission lubricant to
Figure 7-38. Install Retaining Ring With Gap Facing Rear
OD of spacer. With the bevel on the ID toward the trans-
mission case, slide spacer down main drive gear until it
contacts shoulder (quad seal seats in bevel of spacer).
FINAL INSTRUCTIONS
1.
Verify that the two locating dowels are in place on the
right side of the transmission case. Hang a new gasket
on the dowels.
Figure 7-39. Main Drive Gear Large Oil Seal Installer
2.
Squirt a liberal amount of clean transmission lubricant
(Part No. HD-41496)
into the main drive gear to prelube needle bearings.
Install the assembled side door in the transmission case.
See Figure 7-27.
7.
With the beveled side out and the ring gap facing the
3.
Install the four 5/16 inch screws (with flat washers) to
rear, install new retaining ring in groove of bearing bore.
fasten transmission exhaust bracket and bottom of side
Verify that the ring is fully seated in the groove. See Fig-
door to the transmission case. Install the two 1/4 inch
ure 7-38.
screws to fasten the top of the side door to the transmis-
8.
From inside transmission case, carefully position main
sion case. Alternately tighten six screws until snug.
drive gear in bearing bore.
9.
Install backing plate onto 8 inch bolt. From inside trans-
L = 5/16 Inch S = 1/4 Inch
mission case, slide 8 inch bolt through main drive gear
until threaded end exits left side of transmission case.
Pull on end of bolt until backing plate is positioned flat
against inboard side of main drive gear. See Figure 7-
36.
4
2
10.
On left side of transmission case, slide installer cup over
S
S
end of bolt with the open side over the main drive gear.
11.
Sparingly apply graphite lubricant to threads of bolt.
12.
Install Nice bearing, flat washer and hex nut on bolt. See
Figure 7-37.
13.
Holding head of bolt inside transmission case, turn hex
3
L
nut on left side in a clockwise direction until shoulder on
1
main drive gear makes contact with bearing. Remove
L
6
5
L
tool.
L
7969
14.
Obtain the MAIN DRIVE GEAR LARGE OIL SEAL
INSTALLER (HD-41496). See Figure 7-39. Proceed as
follows:
Figure 7-40. Side Door Screw Size and Torque Sequence
2006 Touring: Transmission
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2
4
7
6
1
3
5
Figure 7-42. Final Drive Sprocket Locking Tool
(Part No. HD-41184)
Lubricate
8
f1172a6x
Contact Surfaces
Transmission
Sprocket
1.
Main Drive Gear
5.
Transmission Sprocket
2.
Large Oil Seal
6.
Sprocket Nut
3.
Quad Seal
7.
Lockplate
4.
Spacer
8.
Socket Screw (2)
Figure 7-41. Install Transmission Sprocket Components
4.
Resetting the torque wrench as necessary, tighten the
four 5/16 inch screws to 13-16 ft-lbs (18-22 Nm) and the
two 1/4 inch screws to 84-108 in-lbs (9-12 Nm) in the
sequence shown in Figure 7-40.
5.
Install the transmission sprocket. Install the belt on the
sprocket as the sprocket is installed on the main drive
gear.
6.
Install the sprocket nut. The following procedure is based
Sprocket
on whether a new or used nut is being used.
Locking Tool
f1855x7x
Pivot Shaft
f1856x7x
CAUTION
Exercise caution to avoid getting oil on the threads of
the sprocket nut or the integrity of the lock patch may be
compromised.
New sprocket nut: smear a small quantity of clean
engine oil on the inside face of the sprocket nut and the
outside face of the sprocket. Limit the application to
where the surfaces of the two parts contact each other.
See Figure 7-41. 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
Sprocket
Thumbscrew
Nut
smear a small quantity of Loctite or clean engine oil on
the inside face of the sprocket nut and the outside face
Figure 7-43. Install Final Drive Sprocket Locking Tool
of the sprocket. Limit the application to where the sur-
faces of the two parts contact each other. See Figure 7-
41. Install the sprocket nut until finger tight.
7.
Obtain FINAL DRIVE SPROCKET LOCKING TOOL
a. Insert handle of tool below pivot shaft inboard of
(HD-41184) to lock transmission sprocket. See Figure 7-
bottom frame tube and attach to sprocket. See
42. Proceed as follows:
upper frame of Figure 7-43.
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2006 Touring: Transmission
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a. Install pilot on threaded end of mainshaft. See
upper frame of Figure 7-45.
Wrench
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 7-45. As the nut is tightened the
Pilot
handle of the sprocket locking tool rises to contact
the pivot shaft, thereby preventing sprocket/main-
shaft rotation.
Figure 7-44. Mainshaft Locknut Wrench/Pilot
(Part No. HD-94660-37B )
9.
Scribe a straight line on the transmission sprocket nut
continuing the line over onto the transmission sprocket
as shown in Figure
7-46. Tighten the transmission
sprocket nut an additional 35° to 40°.
10. 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.
11. 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 7-46.
CAUTION
Sprocket
Pilot
f1857x7x
Nut
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation after a torque of 60 ft-lbs (81
f1858x7x
Mainshaft
Nm). Do not loosen sprocket nut to align holes or nut will
Locknut
be under tightened.
Wrench
12. Insert two socket head screws through lockplate into
sprocket holes. Tighten screws to 84-108 in-lbs (9.5-
12.2 Nm).
f1977x6x
Sprocket Nut
Torque
Wrench
45°
35°
Figure 7-45. Install Mainshaft Locknut Pilot/Wrench
and Torque Sprocket Nut
Scribe Line
Transmission
b. Snug thumbscrew to lock position of tool on
on Nut and Sprocket
Sprocket
sprocket. See lower frame of Figure 7-43.
8.
Obtain MAINSHAFT LOCKNUT WRENCH/PILOT (HD-
Figure 7-46. Tighten/Secure Sprocket Nut
94660-37B). See Figure 7-44. Proceed as follows:
2006 Touring: Transmission
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14. If the main drive gear small oil seal was not installed with
the needle bearings (or if a faulty seal is discovered with
Seal Protector
Sleeve
the main drive gear installed in the transmission case),
an alternative method is provided. Proceed as follows:
NOTE
If a serviceable small oil seal is already installed, proceed to
step 15.
Driver
a. Obtain the MAIN DRIVE GEAR SMALL OIL SEAL
INSTALLER (HD-41405). See Figure 7-47.
b. Verify that the lip garter spring is in place on the lip
of the oil seal.
Figure 7-47. Main Drive Gear Small Oil Seal Installer
(Part No. HD-41405 )
c. Place the seal protector sleeve over the end of the
mainshaft.
f1853x7x
d. Lightly lubricate the protector sleeve and ID of oil
seal with clean transmission lubricant.
Small
Oil Seal
e. Squarely seat the oil seal on the seal protector
sleeve with the lip garter spring facing the transmis-
sion case. See upper frame of Figure 7-48.
f.
Lightly apply Loctite RETAINING COMPOUND No.
609 to OD of oil seal.
g. Using the driver, hand press oil seal into the main
drive gear. See lower frame of Figure 7-48. A rubber
mallet may be used to lightly tap the driver, if neces-
sary.
Seal Protector
15.
Install the bearing inner race on the transmission main-
Sleeve
shaft. See Section 6.5 PRIMARY CHAINCASE, MAIN-
SHAFT BEARING INNER RACE, INSTALLATION.
16.
Install shifter cam and fork assemblies. See Section 7.4
f1854x7x
SHIFTER CAM ASSEMBLY/SHIFTER FORKS,
ASSEMBLY.
Driver
17.
Install the starter. See Section 5.4 STARTER, INSTAL-
LATION, steps 1-8.
18.
Install the primary chaincase and starter jackshaft
assembly. Install the clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
19.
Install the exhaust system. See Section 2.38 EXHAUST
SYSTEM, INSTALLATION.
Figure 7-48. Install Small Oil Seal Using
Countershaft Needle Bearing
Seal Protector Sleeve and Driver
Replacement
1.
Find a suitable bearing driver 1-1/4 inch (31.75 mm) in
NOTE
diameter.
The socket head screws have a thread locking compound
2.
From the outside of the transmission case place the nee-
that allows them to be reused up to three times. The fourth
dle bearing open end first next to the bearing bore. Hold
time the screws are removed, replace with new screws (H-D
the driver squarely against the closed end of the bearing
Part No. 3594).
and tap the bearing into place. The bearing is properly
positioned when it is driven inward flush with the outside
13. Complete installation of rear wheel and adjust the belt
surface of the case or to a maximum depth of 0.030 inch
tension. See Section 2.4 REAR WHEEL, INSTALLA-
(0.76 mm).
TION.
3.
Lubricate the bearing with transmission lubricant.
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2006 Touring: Transmission
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TRANSMISSION CASE/OIL PAN
7.8
GENERAL
REMOVAL
The transmission case and oil pan can be removed as an
assembly if the transmission case must be replaced.
Transmission Case and Oil Pan
If necessary, the oil pan can be removed without removing
1.
See Figure 7-49. Remove both the engine oil and trans-
the transmission case. Once the rear wheel is removed, the
mission lubricant drain plugs from the oil pan. Drain the
oil pan can be slid out from the rear.
fluids into suitable containers.
2.
Remove the mainshaft and countershaft assemblies.
See Section
7.6 MAINSHAFT/COUNTERSHAFT,
REMOVAL.
f2267x7x
13
14
12
1.
Screw
9
2.
Screw
3.
Oil hose cover
4.
Oil hose (2)
5.
Hose clamp (6)
11
15
6.
Straight fitting (3)
10
7.
Crankcase
breather hose
8.
Screw (4)
16
9.
Oil filler cap/dipstick
10. Oil filler spout
6
17
11. Filler spout gasket
8
12. Transmission
5
housing
7
13. Dowel pin
4
14. Bolt (4)
5
15. Washer (4)
2
6
16. Ring dowel
17. Baffle spring
18. Serpentine baffle
18
5
19. Oil pan gasket
20. Oil pan
19
21. O-ring (2)
22. Magnetic plug (2)
23. Pipe plug
1
3
24. Screw (12)
20
24
21
Transmission
Drain Plug
21
23
Engine Oil
22
22
Drain Plug
Figure 7-49. Transmission Case and Oil Pan
2006 Touring: Transmission
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7.
Using a side cutters, cut and remove clamps on trans-
7968
mission side of oil supply and return hoses. Pull hoses
Centering
from fittings on transmission housing.
Screw
8.
Cut and remove clamp on transmission side of crank-
case breather hose. Pull hose from fitting on oil filler
spout.
9.
Remove four bolts (with flat washers) to free front of
Washer
transmission from rear of crankcase. Loosen and
remove bolts in a crosswise pattern. Move transmission
Retaining
rearward until two ring dowels in lower flange are free of
Ring
crankcase.
NOTE
If the main drive gear was not removed from the transmission
Transmission
Shift Shaft
case, then it may be removed at this time. See Section 7.7
MAIN DRIVE GEAR/BEARING, REMOVAL.
Figure 7-50. Shifter Pawl Centering Screw
10. Remove the transmission case from the right side of the
motorcycle.
NOTE
Shifter
If removal is difficult, remove the twelve socket head screws
Spring
Shifter
to separate the oil pan from the transmission case. For best
Pawl
results, use a long 3/16 inch ball hex socket driver. Holes in
the lower frame crossmember allow access to bolts which
would not otherwise be accessible.
Slot
Oil Pan Only
Transmission
Centering
Shift Shaft
NOTE
Spring
Perform the following procedure if only the oil pan must be
removed.
7967
1.
See Figure 7-52. Remove both the engine oil and trans-
mission lubricant drain plugs from the oil pan. Drain the
Figure 7-51. Shifter Pawl Assembly
fluids into suitable containers.
3.
Remove rear wheel and rear swingarm. See Section
2.20 REAR SWINGARM, REMOVAL.
f1677x3x
9
NOTE
11
3
The main drive gear and bearing may be removed with the
LEFT
transmission case in the frame. See Section
7.7 MAIN
7
2
SIDE
DRIVE GEAR/BEARING, REMOVAL.
6
4.
Remove the socket head screw from the shift arm.
Remove the shift arm from the transmission shift shaft.
5
Mark splines on transmission shift shaft and shift arm as
8
they are removed to assist in assembly. See Figure 7-50.
5.
Using a T50 TORX drive head, turn the centering screw
RIGHT
1
out until it clears the centering spring slot of the shifter
SIDE
4
pawl assembly. Remove the retaining ring and flat
washer from the transmission shift shaft. See Figure 7-
12
51. Push on end of transmission shift shaft to free shifter
Transmission
10
Engine Oil
Drain Plug
Drain Plug
pawl assembly from transmission case.
6.
Remove two allen head socket screws to release oil
Figure 7-52. Oil Pan Torque Sequence
hose cover. See Figure 7-49.
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2006 Touring: Transmission
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2.
Install lifting strap around frame backbone, and using
2.
Place gasket on oil pan and allow sealer to dry until
overhead jack, support motorcycle from the top.
tacky.
3.
Remove rear wheel. See Section 2.4 REAR WHEEL,
3.
It is normal for the baffle springs to hold the oil pan away
REMOVAL.
from transmission housing. Use a long screwdriver to
4.
With a long 3/16 inch ball hex socket driver (Snap-On
compress the springs as the pan enters the housing.
stock number FABL6 or equal), remove the twelve
Exercise caution to avoid cocking or distorting the
socket head screws from the bottom of the oil pan.
springs.
4.
Position oil pan under transmission and install the twelve
NOTE
oil pan screws, but only tighten about two turns after ini-
Holes in the frame crossmember allow access to bolts which
tial thread engagement.
would not otherwise be accessible.
CAUTION
CAUTION
Inspect the oil pan gasket to ensure that gasket is prop-
Remove the engine oil dipstick before attempting to
erly positioned. If gasket was moved out of position,
slide the oil pan rearward. Contact with the oil pan will
remove screws and repeat step 3 to ensure that gasket is
result in damage to the dipstick.
properly positioned.
5.
Slide oil pan rearward and remove from underside of
5.
Tighten the oil pan screws to 84-132 in-lbs (9.5-14.9
transmission.
Nm) following the numerical sequence shown in Figure
7-52.
6.
Install rear wheel. See Section
2.4 REAR WHEEL,
CLEANING AND INSPECTION
INSTALLATION.
1.
Clean all parts in solvent except the transmission case
7.
Remove lifting strap to release frame backbone from
and needle bearings. Blow dry with compressed air.
overhead jack.
CAUTION
Transmission Case and Oil Pan
The transmission case and needle bearings must not be
cleaned. Normal cleaning methods will wash dirt or other
NOTE
contaminants into the bearing case (behind the needles)
and lead to bearing failure.
If the main drive gear was assembled prior to mounting of the
transmission, place belt on transmission sprocket as trans-
2.
Inspect the shifter pawl and centering spring for wear.
mission is placed in position.
Replace assembly if pawl ends are damaged. Replace
centering spring if elongated.
1.
From right side of motorcycle, place the transmission
3.
Inspect the shifter spring. Replace the spring if it fails to
case (with oil pan) in the frame. Move transmission for-
hold the pawl on the cam pins.
ward until two ring dowels in lower flange fully engage
4.
Thoroughly clean the oil pan with solvent, if removed.
holes in crankcase. Support the engine and transmis-
5.
Inspect the hoses for nicks, cuts or general deterioration.
sion, so that they do not sag at their mating surfaces.
Replace as necessary. Used compressed air to verify
2.
Install the transmission-to-engine mounting bolts as fol-
that hoses and fittings are unobstructed.
lows:
a. Using a crosswise pattern, hand tighten four bolts
INSTALLATION
(with flat washers) to secure transmission housing
to rear of crankcase.
b. Alternately tighten the four bolts to 15 ft-lbs (20.3
Oil Pan Only
Nm) in the same crosswise pattern.
NOTE
NOTE
The following procedure describes installation of the oil pan
For best results, use Open End Crowfoot (Snap-On FC018)
with the transmission case mounted in the motorcycle frame.
on upper left and upper right transmission housing to
Follow the applicable steps to install the oil pan with the
crankcase bolts.
transmission case removed from the motorcycle frame.
1.
Apply a thin coat of HYLOMAR® gasket sealer to gasket
c. Repeating the pattern again, final tighten the four
surface of oil pan.
bolts to 30-35 ft-lbs (40.7-47.5 Nm).
2006 Touring: Transmission
7-33
HOME
10. Install the primary chaincase and starter jackshaft
f1894x7x
assembly. Install clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover. See Section 6.5 PRIMARY CHAIN-
CASE, INSTALLATION.
11. Install rear swingarm and rear wheel. Adjust belt ten-
sion. See Section 2.20 REAR SWINGARM, INSTALLA-
TION.
12. Install engine oil drain plug and tighten to 14-21 ft-lbs
(19-28 Nm).
13. Add engine oil. See Section 3.3 GENERAL INFORMA-
TION, CHANGING ENGINE OIL AND FILTER, steps 9-
12.
Figure 7-53. Shifter Pawl Assembly
3.
Slide new clamps onto free ends of oil supply and return
hoses. See Figure 7-49. Install hoses onto transmission
fittings. Crimp clamps using the Hose Clamp Pliers (HD-
41137).
4.
Slide new clamp onto free end of crankcase breather
hose. Install hose onto fitting of oil filler spout. Crimp
clamp using HOSE CLAMP PLIERS (HD-97087-65B).
5.
Install two allen head socket screws (with captive wash-
ers) to secure oil hose cover to transmission and engine
housings. Longer screw goes to engine housing. Alter-
nately tighten screws to 84-108 in-lbs (10-12 Nm).
6.
Slide splined end of shift shaft through sleeved bore until
it protrudes from left side of transmission case. Install
flat washer and retaining ring on splined end of shift
shaft. Hold the shifter pawl assembly inside the trans-
mission case so that the centering spring slot is aligned
with the centering screw. Using a T50 TORX drive head,
tighten centering screw until snug. See Figure 7-53.
7.
Install the shift arm onto the splined end of the transmis-
sion shift shaft taking note to align marks placed on
splines during disassembly. Install socket head screw
and tighten to 18-22 ft-lbs (24-30 Nm). Make sure screw
registers in slot of shift arm.
8.
Install the mainshaft and countershaft assemblies. See
Section
7.6 MAINSHAFT/COUNTERSHAFT, INSTAL-
LATION.
9.
Install belt on transmission sprocket.
7-34
2006 Touring: Transmission
Table Of Contents
SUBJECT
PAGE NO.
8.1 Specifications
8-1
8.2 Bulb Chart
8-3
8.3 System Fuses
8-5
8.4 ICM (Carbureted)
8-7
8.5 Sensors (Carbureted)
8-8
8.6 Ignition Coil
8-9
8.7 Spark Plugs/Spark Plug Cables
8-10
8.8 Alternator/Stator
8-12
8.9 Voltage Regulator
8-15
8.10 Battery
8-17
8.11 Headlamp (FLHR/C/S, FLHX, FLHT/C/U)
8-23
8.12 Headlamp (FLTR)
8-26
8.13 Auxiliary Lamps
8-29
8.14 Tail Lamp Assembly
8-34
8.15 Fender Tip Lamps
8-38
8.16 Turn Signal Lamps
8-43
8.17 License Plate Lamps/Bracket (FLHX)
8-52
8.18 TSM/TSSM
8-54
8.19 Ignition/Light Key Switch And Fork Lock
8-55
8.20 Fairing Cap Switches (FLHTC/U)
8-60
8.21 Instrument Nacelle Switches (FLTR)
8-62
8.22 Handlebar Switches
8-66
8.23 Stoplight Switches
8-83
8.24 Neutral Switch
8-84
8.25 Oil Pressure Switch/Sender
8-85
8.26 Horn
8-86
8.27 Cigarette Lighter (FLHX, FLHT/C/U, FLTR)
8-87
8.28 Gauges/Instruments (FLHX, FLHT/C/U, FLTR)
8-88
8.29 Gauges/Instruments (FLHR/C/S)
8-92
8.30 Fuel Level Sender (Carbureted)
8-96
8.31 Cruise Control (FLHRC, FLHTCU, FLTR)
8-101
8.32 Advanced Audio System (FLHX, FLHTC/U, FLTR)
8-109
8.33 Wire Trough
8-116
8.34 Main Harness
8-119
8.35 Interconnect Harness
8-133
8.36 Radio Antenna Cable
8-141
8.37 Audio Harness (FLHTCU)
8-145
8.38 CB Antenna Cable (FLHTCU)
8-149
ELECTRICAL
8
NOTE
See the 2006 ELECTRICAL DIAGNOSTIC MANUAL
(Part No. 99497-06) for all SYSTEM DIAGNOSIS and
ELECTRICAL TROUBLESHOOTING information.
HOME
SPECIFICATIONS
8.1
IGNITION TIMING
System Fuse Block (Under Left Side Cover)
ALL FL Models
8
FLHR/C/S
RANGE
TDC - 50˚ BTDC
9
10
START
TDC
5
11
ALTERNATOR SYSTEM
Output Voltage @ 3600 rpm 14.3-14.7
4
12
50 Amp: All Models
f2210x8x
3
1
2
BATTERY
8
7
FLHX, FLHT/C/U, FLTR
Voltage 12V
9
6
10
Amperes - 28 AH @ 20 Hour Rate
5
11
FUSES
4
Rating
Circuit
Color
(Amperes)
System Fuses
f2204x8x
2
3
1
Maxi-Fuse
40
Orange
1.
Headlamp
7.
Radio Power
Headlamp
15
Blue
2.
Ignition
8.
Accessory
3.
Lighting
9.
Battery
Ignition
15
Blue
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
Lighting
15
Blue
6.
Radio Memory
12.
Starter Relay
Instruments
15
Blue
Brakes/Cruise
15
Blue
EFI Fuse Block (Under Right Side Cover)
Radio Memory
15
Blue
EFI System
Radio Power
10
Red
Relay
Spare
Accessory
15
Blue
Battery
15
Blue
Fuel Pump
P & A
15
Blue
EFI Fuses
ECM Power
Fuel Pump
15
Blue
f2223x9x
ECM Power
15
Blue
Figure 8-1. Fuse Locations
2006 Touring: Electrical
8-1
HOME
SPARK PLUG
Item
ft/in-lbs
Nm
Part No.
No.
Size
Gap
Instrument bezel TORX
25-35 in-lbs
2.8-4.0 Nm
screws
0.038-0.043 in.
32317-86A
6R12
12 mm
0.97-1.09 mm
Handlebar clamp to
master cylinder housing
60-80 in-lbs
6.8-9.0 Nm
screws
NOTE
Lower and upper handle-
Be sure spark plugs are gapped to specification before instal-
bar switch housing TORX
35-45 in-lbs
4-5 Nm
lation.
screws
Handlebar clamp to
clutch lever bracket TORX
60-80 in-lbs
6.8-9.0 Nm
screws
TORQUE VALUES
Neutral switch
120-180 in-lbs
13.6-20.3 Nm
Horn stud flange nut
80-100 in-lbs
9.0-11.3 Nm
(10mm)
Item
ft/in-lbs
Nm
Horn bracket acorn nut to
80-100 in-lbs
9.0-11.3 Nm
Ignition module socket
rubber mount stud
50-60 in-lbs
5.7-6.8 Nm
head screws
2 inch diameter gauge
10-20 in-lbs
1.1-2.3 Nm
MAP sensor TORX screw
25-35 in-lbs
2.8-4.0 Nm
nuts
Ignition coil bracket
Tachometer bracket
84-144 in-lbs
9.5-16.3 Nm
10-20 in-lbs
1.1-2.3 Nm
socket screws
socket screws
Spark plug
12-18 ft-lbs
16-24 Nm
Speedometer speed
84-108 in-lbs
9-12 Nm
sensor screw
Stator to crankcase TORX
55-75 in-lbs
6.2-8.5 Nm
screws
Speedometer bracket
10-20 in-lbs
1.1-2.3 Nm
socket screws
Battery cable bolt
60-96 in-lbs
6.8-10.9 Nm
Console mounting bolt
Voltage regulator locknuts
70-100 in-lbs
7.9-11.3 Nm
50-90 in-lbs
5.7-10.2 Nm
acorn nut (FLHR/C/S)
Battery hold-down clamp
15-20 ft-lbs
20-27 Nm
Console pod Phillips
TORX screw
6-11 in-lbs
0.7-1.2 Nm
screws
Headlamp door screw
9-18 in-lbs
1.0-2.0 Nm
Fuel tank canopy TORX
18-24 in-lbs
2.0-2.7 Nm
Auxiliary lamp bracket to
screws
15-20 ft-lbs
20-27 Nm
fork bracket TORX bolts
Cruise module locknuts
60-96 in-lbs
6.8-10.9 Nm
Auxiliary lamp bracket to
Radio to support bracket
fork bracket stud acorn
72-108 in-lbs
8.1-12.2 Nm
35-45 in-lbs
4.0-5.1 Nm
socket screws
nuts
Upper fairing speaker
Tail lamp lense screws
20-24 in-lbs
2.3-2.7 Nm
22-28 in-lbs
2.5-3.2 Nm
lower TORX screw
Tail lamp circuit board/
40-48 in-lbs
4.5-5.4 Nm
Upper fairing speaker
chrome base screw
35-50 in-lbs
4.0-5.7 Nm
upper TORX screws
Rear fender tip lamp nuts
20-25 in-lbs
2.3-2.8 Nm
Throttle cable J-clamp
Front fender tip lamp nuts
20-25 in-lbs
2.3 - 2.8 Nm
screw to wellnut
9-18 in-lbs
1.0-2.0 Nm
Front fender trim strip tee
(FLHR/C/S)
10-15 in-lbs
1.1-1.7 Nm
bolt nuts
Ground post flange nuts
50-90 in-lbs
5.7-10.2 Nm
Ignition switch to upper
VSS screw
84-132 in-lbs
9.5-14.9 Nm
36-60 in-lbs
4.1-6.8 Nm
fork bracket
Rear stoplight switch
12-15 ft-lbs
16.3-20.3 Nm
Fairing cap TORX screws
25-30 in-lbs
2.8-3.4 Nm
Rear fender lights harness
60-96 in-lbs
6.8-10.9 Nm
Ignition switch nut
125-150 in-lbs
14.1-16.9 Nm
stud plate flange nut
Fork lock to upper fork
36-60 in-lbs
4.1-6.8 Nm
bracket (FLHR/C/S)
Ignition switch screws
20-30 in-lbs
2.3-3.4 Nm
(FLHR/C/S)
Continued ...
8-2
2006 Touring: Electrical
HOME
BULB CHART
8.2
Lamp Description,
Number of
Current Draw
Harley-Davidson
Wattage
All Lamps 12V
Bulbs
(Amperage)
Part No.
HEADLAMP
FLHR/C/S, FLHX, FLHT/C/U,
1
4.58/5
55/60
68329-03
FLTR
2
4.58/5
55/60
68329-03
POSITION LAMP (HDI)
1
0.32
3.9
53438-92
AUXILIARY LAMPS
(DOM)
2
2.10
26.9
68453-05
(HDI)
2
2.70
35.0
68851-98
TAIL AND STOP LAMP
1
Tail Lamp
0.59
6
68167-88
Stop Lamp
2.10
24
68167-88
Tail Lamp (HDI)
0.59
6
68167-88
Stop Lamp(HDI)
2.10
24
68167-88
License Plate (HDI)
1
0.37
5.2
53436-97
TURN SIGNAL LAMP
Front/Running
2
2.25/.59
27/7
68168-89
Front (HDI)
2
1.75
21
68163-84
Rear
2
2.25
27
68572-64B
Rear (HDI)
2
1.75
21
68163-84
TOUR-PAK
Side Marker Lamps **
Tail/Brake Lamps (Ultra)
2
0.59
7
68168-89A
FENDER TIP LAMPS *
2
0.3
3.7
53439-79
LICENSE PLATE
2
0.35
-
52441-95
LAMPS (FLHX)
INSTRUMENT PANEL LAMPS
FLHX, FLHT/C/U, FLTR
High Beam
1
0.15
2.1
68024-94
Oil Pressure
1
0.15
2.1
68024-94
Neutral
1
0.15
2.1
68024-94
Turn Signal
2
0.15
2.1
68024-94
GAUGE LAMPS
FLHX, FLHT/C/U, FLTR
Speedometer **
Tachometer **
Voltmeter
1
0.24
3.4
67445-00
Oil Pressure Gauge
1
0.24
3.4
67445-00
Air Temperature Gauge
1
0.24
3.4
67445-00
Fuel Gauge
1
0.24
3.4
67445-00
Engine **
INSTRUMENT PANEL/
GAUGE LAMPS
FLHR/C/S
High Beam **
Oil Pressure **
Neutral **
Turn Signal **
Fuel Gauge **
Speedometer **
Odometer **
Engine **
* Not Applicable to HDI
** LED Illuminated. LEDs are not repairable. Assembly must be replaced if LED fails.
2006 Touring: Electrical
8-3
HOME
NOTES
8-4
2006 Touring: Electrical
HOME
SYSTEM FUSES
8.3
MAXI-FUSE
REMOVAL
1.
Remove left side saddlebag. See Section 2.26 SAD-
DLEBAG, REMOVAL.
2.
Gently pull side cover from frame downtubes (no tools
required).
3.
Depress latches on maxi-fuse holder and then slide
cover rearward to disengage tongue from groove in fuse
block cover. See Figure 8-2.
f2207x8x
4.
Pull maxi-fuse from maxi-fuse holder. See Figure 8-3.
Figure 8-3. Remove Maxi-Fuse
INSTALLATION
MAXI-FUSE HOLDER
1.
Insert maxi-fuse into maxi-fuse holder. See Figure 8-3.
2.
Slide cover forward to engage tongue in groove of fuse
REMOVAL
block cover and then insert maxi-fuse holder into cover
until latches engage. See Figure 8-2.
1.
Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
section.
3.
Align barbed studs in side cover with grommets in frame
downtubes and push firmly into place
(no tools
2.
Remove socket terminals from maxi-fuse holder. See
required).
Section B.4 PACKARD ELECTRICAL CONNECTORS,
800 METRI-PACK SERIES.
4.
Install left side saddlebag. See Section 2.26 SADDLE-
BAG, INSTALLATION.
INSTALLATION
3.
Install socket terminals into maxi-fuse holder. See
Section B.4 PACKARD ELECTRICAL CONNECTORS,
800 METRI-PACK SERIES.
4.
Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
SYSTEM FUSES/RELAYS
REMOVAL
Fuse
Maxi-Fuse
1.
Remove maxi-fuse. See MAXI-FUSE, REMOVAL, in this
Block
Cover
section.
f2206x8x
2.
Pull fuse block from tabs on mounting bracket. Tabs on
Figure 8-2. Remove Left Side Cover
bracket fit into slots on each side of fuse block cover.
2006 Touring: Electrical
8-5
HOME
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
Fuse Block
Cover
INSTALLATION
1.
Install system fuse/relay in fuse block. See Figure 8-5.
NOTE
For FLHR/C/S configuration, see upper frame of Figure 8-1 in
Section 8.1 SPECIFICATIONS.
Spare Fuse
2.
Slide cover over fuse block until slots fully engage tabs
Holder
on block. See Figure 8-4.
f2209x8x
3.
Slide fuse block into position on mounting bracket. Tabs
Figure 8-4. Fuse Block Cover
on bracket fit into slots on each side of fuse block cover.
4.
Install maxi-fuse. See MAXI-FUSE, INSTALLATION, in
this section.
f2203x8x
8
7
9
6
FUSE BLOCK
10
5
11
REMOVAL
1.
Remove system fuses and relay(s). See SYSTEM
FUSES/RELAYS, REMOVAL, in this section.
4
2.
Remove socket terminals from fuse block. See Section
B.4 PACKARD ELECTRICAL CONNECTORS,
280
METRI-PACK SERIES.
1
2
3
1.
Headlamp
INSTALLATION
2.
Ignition
7.
Radio Power
3.
Lighting
8.
Accessory
1.
Install socket terminals into fuse block. See Section B.4
4.
Instruments
9.
Battery
PACKARD ELECTRICAL CONNECTORS, 280 METRI-
5.
Brakes/Cruise
10. Brake Light Relay
PACK SERIES.
6.
Radio Memory
11. P&A
2.
Install system fuses and relay(s). See SYSTEM FUSES/
RELAYS, INSTALLATION, in this section.
Figure 8-5. Fuse Block (FLHX, FLHTC/U, FLTR)
NOTE
EFI FUSES
The fuse block cover also serves as the spare fuse holder.
One spare 10 amp and 15 amp fuse are provided.
See Section 9.2 ELECTRICAL BRACKET ASSEMBLY, EFI
SYSTEM RELAY/EFI FUSES.
3.
Remove the fuse block cover. Raise lipped side slightly
to disengage slots from tabs on fuse block. See Figure
8-4.
4.
Remove system fuse/relay from fuse block. Replace
fuse if the element is burned or broken. Automotive type
ATO fuses are used. See Figure 8-5.
8-6
2006 Touring: Electrical