Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

3. Remove the clutch spring cover.

4. Remove the quad ring (A, Figure 14).

5. Remove the spring and lockplate (B, Figure 14).

6. Turn the clutch adjusting screw (A, Figure 15) clock-
wise and release the ramp (B) and coupling (C). Turn the
clutch adjusting screw clockwise to move the ramp assem-
bly forward. Then unscrew the nut (D, Figure 15) from the
end of the adjusting screw and remove it.

7. Pivot the hook on the ramp to the rear of the cable end cou-
pling. Disconnect and remove the clutch cable from the slot in
the coupling. Remove the coupling and ramp assembly.

8. Remove the snap ring (Figure 22) securing the inner
and outer ramp halves. Separate the halves and remove the
ramps and balls.

Inspection

1. Wash the clutch release mechanism in solvent and dry
thoroughly.

2. Check the balls and ramp sockets (Figure 23) for pit-
ting, severe wear or other damage.

3. Check the adjusting screw (Figure 24) for thread or
bearing damage.

4. Replace the lockplate if the tabs are weak or broken.

5. Replace severely worn or damaged parts as required.

Installation

Refer to Figure 12.

1. Apply grease to the ball and ramp surfaces (Figure 23)
and insert the balls into the outer ramp sockets.

2. Install the inner ramp on the outer ramp hook so the
punch mark (A, Figure 25) on the inner ramp aligns with
the hook of the outer ramp (B).

3A. On 1994-1996 models, install the coupling onto the
cable end with the rounded side facing out and the ramp
connector button facing in.

3B. On 1997-2003 models, install the coupling onto the
cable end with the rounded side facing in and the ramp
connector button facing out. With the retaining side of the
ramp facing in, install the ramp hook around the coupling
button. Then rotate the assembly counterclockwise until
the tang on the inner ramp fits into the primary drive cover
slot.

4. Thread the nut onto the clutch adjusting screw until the
slot in the end of the screw is accessible with a screwdriver.
Then align and install the hex portion on the nut into the
outer ramp recess (Figure 26). Turn the clutch adjusting
screw counterclockwise until resistance is felt, then back
off 1/4 turn.

5. Adjust the clutch as described in Chapter Three. The
spring and lockplate shown in B, Figure 14 will be in-
stalled during the clutch adjustment procedure.

270

CHAPTER SEVEN

PRIMARY CHAIN ADJUSTER

Refer to Figure 27.
The primary chain adjuster assembly is mounted inside

the primary drive cover.

Removal

1. Remove the primary drive cover as described in this
chapter.
2. Remove the adjuster screw locknut (A. Figure 28).
3. Turn the adjuster screw (B, Figure 28) to remove it from
the threaded boss in the primary drive cover.
4. Slide the adjuster shoe (C, Figure 28) off the shoe plate.
5. Remove the upper locknut and shoe plate.

Inspection

1. Clean all parts in solvent and dry thoroughly.
2. Replace the adjuster shoe (C, Figure 28) if severely
worn or damaged.
3. Replace the shoe plate if bent or otherwise damaged.
4. Replace the locknut(s) and adjuster screw if thread dam-
age is apparent.

Installation

1. Install the shoe plate over the top of the adjuster screw.
2. Place the spacer over the top of the adjuster screw and
rest it on top of the shoe plate.
3. Thread the upper primary chain adjuster locknut onto
the top of the adjuster screw. Tighten the upper locknut to
120-144 in.-lb. (14-16 N•m).
4. Slide the open side of the adjuster shoe over the shoe
plate until the upper locknut is positioned against the closed
side of the shoe.
5. Place the adjuster assembly into the primary drive cover
so that the closed side of the adjuster shoe (C, Figure 28)
faces toward the primary drive cover.
6. Thread the adjuster screw (B, Figure 28) into the boss at
the bottom of the primary drive cover.
7. Thread the lower locknut (A, Figure 28) onto the ad-
juster screw.
8. Install the primary drive cover as described in this chapter.
9. Adjust the primary chain (Chapter Three).

PRIMARY DRIVE/CLUTCH

Refer to Figure 29.

Tools

Complete disassembly of the clutch requires the use of a

clutch spring compression tool (Figure 30 [part No.
HD-38515A, 38515-90/91 or equivalent]). If the compres-

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

271

PRIMARY CHAIN ADJUSTER

Open side

Nylon sealing
surface

1. Shoe
2. Upper locknut
3. Spacer
4. Shoe plate

5. Adjuster screw
6. Primary drive

cover

7. Lower locknut

sion tool is not available, remove the clutch intact from the
motorcycle and take it to a dealership for disassembly or
service. Do

not

attempt to disassemble the clutch without

the tool.

Clutch/Primary Chain/Engine Sprocket Removal
(Clutch is Not Disassembled)

This procedure describes removal of the clutch, primary

chain and engine sprocket, which allows later clutch disas-
sembly as described in

Clutch Hub and Shell Disassem-

bly/Reassembly

in this section. If clutch disassembly with

the clutch mounted on the motorcycle is desired, refer to

Clutch Disassembly on Motorcycle

in this section.

1. Shift the transmission into 5th gear.

2. Disconnect the negative battery cable (Chapter Twelve).

3. Remove the primary drive cover as described in this
chapter.

4. Install the sprocket locking link (part No. HD-38362 or
equivalent) between the engine sprocket and clutch shell as
shown in Figure 31.

5. Remove the engine sprocket nut (A, Figure 32).

6. Loosen the engine sprocket by pulling it (do not remove
it). If the engine sprocket is tight, break it loose with a
puller and two bolts installed on the sprocket face (B, Fig-
ure 32).

7. Remove the snap ring (Figure 33) holding the release
plate/adjusting screw in position.

8. Remove the release plate/adjusting screw assembly
(Figure 34).

9. The clutch nut (Figure 35) has left-hand threads. Turn
the clutch nut clockwise to loosen it. Then remove the
clutch nut and washer (Figure 36).

10. Remove the locking link (Figure 31).

11. Remove the engine sprocket, primary chain and clutch
as an assembly (Figure 37).

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

273

Clutch Disassembly on Motorcycle

This procedure describes disassembly of the clutch while

it is mounted on the motorcycle. Engine sprocket and pri-
mary chain removal is not required. Read this procedure
completely before starting disassembly.

1. Disconnect the negative battery cable (Chapter Twelve).

2. Remove the primary drive cover as described in this
chapter.

WARNING

Do not attempt to disassemble the clutch
without using a clutch spring compression
tool. (

Figure 30

[part No. HD-38515A, part

No. 38515-90/91 or equivalent]). The dia-
phragm spring snap ring (12,

Figure 29

) is

held under considerable pressure and will fly
out if pressure is not first removed.

3. To remove the diaphragm spring snap ring, perform the
following:

a. Thread the clutch spring compression tool forcing

screw onto the clutch adjusting screw as shown in
Figure 38.

b. Position the spring compression tool (Figure 39)

against the diaphragm spring and thread the tool han-
dle onto the end of the forcing screw.

CAUTION

Turn the cltuch compression tool handle only
the amount required to compress the dia-
phragm spring and remove the snap ring. Ex-
cessive compression of the diaphragm spring
may damage the clutch pressure plate.

c. Hold the compression tool forcing screw with a

wrench (Figure 40) and turn the tool handle clock-
wise to compress the diaphragm spring.

d. Remove the snap ring (Figure 41) and spring seat

(Figure 42) from the groove in the clutch hub.

e. Remove the diaphragm spring, pressure plate, clutch

adjusting screw and spring compressing tool as an as-
sembly; see Figure 43.

274

CHAPTER SEVEN

NOTE

Do not loosen the spring compressing tool to
remove the diaphragm spring or pressure
plate unless these parts require close inspec-
tion or replacement. Loosening and removing
the clutch compression tool requires reposi-
tioning of the diaphragm spring during reas-
sembly. This step will not be required as long
as the compression tool is not removed from
these parts.

4. Remove the friction and steel clutch plates (Figure 44)
and the spring plate, from the clutch assembly in the order
shown in Figure 29. Note the spring plate installed between
the fourth and fifth friction plates (Figure 45).

NOTE

Further removal steps are not required unless
it is necessary to separate the clutch hub and
shell assembly. Remove these parts as de-
scribed in

Clutch Hub and Shell Disassem-

bly/Reassembly

in this section.

Clutch Inspection

1. Clean all parts, except friction plates and bearings, in a
non-oil based solvent and thoroughly dry with compressed
air. Place all cleaned parts on lint free paper towels.
2. Check each steel plate (A, Figure 46) for visual damage
such as cracks or wear grooves. Then place each plate on a
surface plate, such as piece of glass, and check for warp

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

275

with a feeler gauge. Replace the steel plates as a set if any
one plate is warped more than 0.006 in. (0.15 mm).

3. Inspect the friction plates (B, Figure 46) for worn or
grooved lining surfaces. Replace the friction plates as a set if
any one plate is damaged. If the friction plates do not show vi-
sual wear or damage, wipe each plate thoroughly with a
lint-free cloth to remove as much oil from the plates as possi-
ble. Measure each plate individually and compare to the mea-
surements in Table 1. Stack each of the eight friction plates on
top of each other and measure the thickness of the assembly.
Replace the friction plates as an assembly if the combined
thickness of the eight plates is less than 0.661 in. (16.79 mm).

4. Measuer each steel plate and compre the thickness to the
specification in Table 1. Replace if not within specification.

5. Check the spring plate (C, Figure 46) for cracks or dam-
age. Check for loose or damaged rivets. Replace the spring
plate if necessary.

6. Check the clutch diaphragm spring for cracks or dam-
age. Check also for bent or damaged tabs. Replace the dia-
phragm spring if necessary.

7. A ball bearing is pressed into the clutch shell and the
clutch hub is pressed into the bearing. Hold the clutch hub
and rotate the clutch shell by hand. The shell should turn
with no sign of roughness or tightness. If the clutch shell
binds or turns roughly, the bearing is damaged and must be
replaced. Refer to Step 10.

8. The steel clutch plate inner teeth mesh with the clutch
hub splines. Check the splines for cracks or galling. They
must be smooth for chatter-free clutch operation. If the
clutch hub splines are damaged, the clutch hub must be re-
placed; refer to Step 10.

9. The friction plates (B, Figure 46) have tabs that slide in the
clutch shell grooves. Inspect the shell grooves for cracks or
wear grooves. The grooves must be smooth for chatter-free
clutch operation. If the clutch shell grooves are damaged or
worn severely, replace the clutch shell; refer to Step 10.

10. Check the primary chain sprocket and the starter ring
gear on the clutch shell for cracks, deep scoring, excessive
wear or heat discoloration. If either the sprocket or ring gear
is severely worn or damaged, replace the clutch shell; refer to
Step 11. If the sprocket is worn, also check the primary chain
and the engine sprocket as described in this chapter.

11. If the clutch hub, shell or bearing require replacement,
refer to

Clutch Hub and Shell Disassembly/Reassembly

this section.

Primary Chain

Replace the primary chain if severely worn or damaged.

Do not attempt to repair the chain. If the primary chain is
worn or damaged, check the engine sprocket and clutch shell
sprocket for wear or damage. Replace parts as required.

276

CHAPTER SEVEN

Clutch Hub and Shell
Disassembly/Reassembly

The clutch hub and shell should not be separated unless

replacement of the hub, shell or bearing is required. Disas-
sembly of the hub and shell will damage the ball bearing;
bearing replacement will be required during reassembly.

A press is required for this procedure.

1. Remove the clutch plates from the clutch hub and shell
assembly, if they have not been previously removed. Refer
to

Clutch Disassembly on Motorcycle

in this section.

2. Remove the snap ring from the clutch hub groove (Fig-
ure 47).
3. Support the clutch hub and shell in a press (Figure 48)
and press the clutch hub out of the bearing. See Figure 49.
Remove the clutch shell from the press.
4. Locate the snap ring (Figure 50) securing the bearing in
the clutch shell and remove it.
5. The bearing must be removed through the front side of
the shell. The clutch shell is manufactured with a shoulder
on the rear (primary chain) side. Support the clutch shell in
the press and press the bearing out of the shell. Discard the
bearing.
6. Discard worn or damaged parts. Clean reusable and new
parts, except bearings and snap rings, in non-oil based sol-
vent and dry thoroughly.
7. Place the clutch shell into the press. Align the bearing
with the clutch shell and press the bearing into the shell un-
til the bearing bottoms out against lower shoulder. When
pressing the bearing into the clutch shell, press only on the
outer bearing race. Refer to

Service Procedures

in Chapter

One for additional information.
8. Install a new bearing snap ring into the clutch shell
groove (Figure 50). Make sure the snap ring seats in the
groove completely.
9. Press the clutch hub into the clutch shell as follows:

CAUTION

Failure to support the inner bearing race
properly will cause bearing and clutch shell
damage. Refer to

Figure 51

to make sure the

inner hearing race is supported properly.

a. Place the clutch shell in a press. Support the inner

bearing race with a sleeve as shown in Figure 51.

b. Align the clutch hub with the bearing and press the

clutch hub into the bearing until the clutch hub shoul-
der seats against the bearing.

c. Install a new clutch hub snap ring (Figure 47). Make

sure the snap ring seats in the clutch hub groove com-
pletely.

10. After completing assembly, hold the clutch hub and ro-
tate the clutch shell by hand. The shell should turn
smoothly with no roughness or binding. If the clutch shell
binds or turns roughly, the bearing may have been damaged
during reassembly. Correct before installing.

Clutch Assembly

After assembly, the clutch will be installed back onto the

motorcycle. If the clutch assembly was not disassembled,
refer to

Clutch Installation

in this section.

Refer to Figure 29.

NOTE

Before installing the clutch plates, count the
number of each plate. The set should include
eight friction plates, six steel plates and one
spring plate.

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

277

Clutch
shell

Clutch hub

Press

Bearing

Sleeve

1. Soak all of the clutch plates in clean transmission oil for
approximately 5 minutes before installing them.
2. Align the tabs on a friction plate with the clutch shell
grooves and install the plate. Then align the inner teeth on a
steel plate with the clutch hub grooves and install the plate.
Repeat until all of the clutch plates have been installed. In-
stall the spring plate (Figure 45) between the fourth and
fifth friction plates. The last plate installed must be a fric-
tion plate.

NOTE

During clutch removal, if the spring com-
pressing tool was not removed from the dia-
phragm spring and pressure plate, proceed to
Step 4. If the spring compressing tool was re-
moved and the clutch diaphragm spring was
separated from the pressure plate, continue
with Step 3.

3. Assemble the pressure plate and clutch diaphragm
spring as follows:

a. Install the adjusting screw assembly (release plate,

snap ring, bearing and adjusting screw) into the pres-
sure plate. Install the release plate by aligning its tabs
with the slots in the pressure plate. Secure the release
plate by installing the retaining ring into the pressure
plate groove. Make sure the retaining ring seats in the
groove completely.

b. The diaphragm spring is concave. Install the dia-

phragm spring onto the pressure plate so the concave
side faces the pressure plate—the convex side must
face out.

c. Install the spring seat with its flat, larger outer diame-

ter side facing toward the diaphragm spring.

WARNING

Because of the force required to compress the
diaphragm spring when installing the snap
ring, a clutch spring compression (part
No.HD-38515A, 38515-90/91 or equivalent)
must be used. Severe personal injury from the
diaphragm spring flying out could occur if
the special tool is not used.

4. To install the diaphragm spring snap ring, use a clutch
spring compression tool to perform the following:

a. Thread the spring compression tool forcing screw

onto the clutch adjusting screw.

b. Position the spring compression tool against the dia-

phragm spring and thread the tool handle onto the
end of the forcing screw. Do not apply pressure
against the diaphragm spring at this time.

c. Align the square holes in the pressure plate and dia-

phragm spring with the prongs on the face of the
clutch hub. Then place the spring seat, snap ring, dia-
phragm spring, pressure plate, adjusting screw as-
sembly and compressing tool onto the clutch hub
(Figure 43).

CAUTION

Turn the compression tool handle only the
amount required to compress the diaphragm
spring and install the snap ring. Excessive
compression of the diaphragm spring may
damage the clutch pressure plate.

d. Hold the compression tool forcing screw with a

wrench and turn the tool handle clockwise to com-
press the diaphragm spring.

e. Install the spring seat and snap ring into the groove in

the clutch hub.

f. After making sure the snap ring is seated completely

in the clutch hub groove, turn the compressing tool
handle counterclockwise while checking that the
clutch spring seat lip seats inside the snap ring. After
all tension has been removed from the compressing
tool, remove it from the release plate.

278

CHAPTER SEVEN

5. Remove the release plate retaining ring. Then remove
the adjusting screw assembly (release plate, retaining ring,
bearing and adjusting screw).

Clutch Installation

CAUTION

The rotor is mounted on the engine sprocket.
Carefully inspect the inside of the rotor for
small bolts, washers or other metal debris
that may have been picked up by the magnets.
This debris can cause severe damage to the
alternator stator assembly.

1. Assemble the clutch assembly as described in this section.
2. The engine sprocket, primary chain and clutch are in-
stalled as an assembly. Assemble the engine sprocket,
clutch and primary chain as shown in Figure 52.
3. Lift the primary drive assembly as a unit and slide the
engine sprocket and clutch into the primary chaincase. See
Figure 53.
4. Install a sprocket locking link (Figure 54) (part No.
HD-38362 or equivalent) between the engine sprocket and
clutch shell.

CAUTION

The engine sprocket is tightened to a high
torque specification. Be sure to hold the
sprocket securely when tightening the nut.

5. Apply 2-3 drops of Loctite 262 (red) to the engine
sprocket nut threads and install the nut (Figure 55) onto the
sprocket shaft. Tighten the engine sprocket nut to the torque
specified in Table 2.
6. Install the clutch nut Belleville washer onto the
mainshaft so that the word OUT on the washer faces away
from the engine (Figure 56).
7. Apply threadlock (Loctite 262 or equivalent) to the
clutch nut threads and install the nut onto the mainshaft by
turning the nut counterclockwise. Tighten the clutch nut
(Figure 57) to 70-80 ft.-lb. (96-108 N•m).
8. Remove the sprocket locking link (Figure 54).
9. Install the adjusting screw assembly (Figure 58) by
aligning the two tabs on the release plate perimeter with the
two recesses in the pressure plate.
10. Install a new retaining ring (Figure 59).
11. Install the primary drive cover as described in this chapter.
12. Adjust the primary chain (Chapter Three).
13. Refill the primary chain housing (Chapter Three).
14. Reconnect the negative battery cable (Chapter Twelve).

CLUTCH CABLE

Replacement

1991-1993 models

Refer to Figure 60.

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

279

1. Remove the primary drive cover as described in this chapter.
2. Pry the lockplate tabs (A, Figure 61) away from the
mounting screws and remove the lockplate and screws.
3. Remove the clutch release mechanism from the cover
and disconnect the cable (B, Figure 61) from the ramp and
coupling. Remove the release clutch mechanism (C, Figure
61).
4. Turn the clutch cable (Figure 62) counterclockwise and
remove it from the primary drive cover.
5. Remove the O-ring (Figure 63) from the lower cable
end fitting.
6. At the clutch lever, remove the pivot pin circlip and re-
move the pivot pin (2, Figure 64).
7. Slide the clutch lever out of the bracket (3, Figure 64).
8. Remove the clutch cable and disconnect the clutch cable
from the lever (12, Figure 64).
9. Remove the screw and anti-rattle spring from the bottom
of the clutch lever (6, Figure 64).
10. Note the cable routing before removing it. The new ca-
ble must be routed along the same path. Slide the clutch ca-
ble through the guide clip (Figure 65) and remove the
clutch cable.
11. Slide the O-ring over the lower cable end fitting (Figure
63) and insert the cable into the primary drive cover. Turn the
cable (Figure 62) clockwise and tighten it securely.
12. Connect the lower end of the clutch cable to the cable
coupling. Connect the cable coupling to the outer ramp
(Figure 60).
13. Install the clutch release mechanism and lockplate onto
the primary drive cover with the mounting screws. Tighten
the screws securely. Bend the lockplate tabs over the screw
heads to lock them.
14. Install the primary drive cover as described in this chapter.
15. Route the clutch cable as shown in Figure 66.

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

281

CLUTCH LEVER ASSEMBLY

1. Clutch cable
2. Pivot pin
3. Clutch lever bracket
4. Snap ring
5. Clutch cable pin
6. Anti-rattle spring

(1991-1996 models)

7. Screw

(1991-1996 models)

8. Clamp
9. Washer

10. Screw
11. Bushing
12. Clutch lever

CLUTCH CABLE ROUTING

1. Clutch lever
2. Rubber boot
3. Clutch cable
4. Clamp
5. Cable end

fitting

16. Install the anti-rattle spring and screw onto the clutch
lever (12, Figure 64).

17. Connect the clutch cable to the clutch lever and secure
it with the clutch cable pin (5, Figure 64).

18. Install the clutch lever into the bracket (3, Figure 64).

19. Wipe the pivot pin shoulder with a small amount of
anti-seize compound. Install the pivot pin through the
clutch bracket and lever and secure it with the snap ring (4,
Figure 64).

20. Adjust the clutch (Chapter Three).

1994-2003 models

Refer to Figure 67.

CAUTION

When removing the clutch spring cover (

Figure 67

), do not remove or damage the

quad ring (

) in the primary drive cover.

1. Remove the clutch spring cover.

2. Remove the spring and lockplate.

3. Turn the clutch adjusting screw clockwise and release
the ramp and coupling mechanism.

4. Turn the clutch adjusting screw clockwise to move the
ramp assembly forward. Then unscrew the nut from the end
of the adjusting screw and remove it.
5. Pivot the hook on the ramp to the rear of the cable end
coupling. Then disconnect and remove the clutch cable
from the coupling slot.
6. Turn the clutch cable (Figure 62) counterclockwise and
remove it from the primary drive cover.
7. Remove the O-ring (Figure 63) from the lower cable
end fitting.
8. At the clutch lever, remove the pivot pin snap ring (4,
Figure 64) and remove the pivot pin (2).
9. Slide the clutch lever out of its bracket (3, Figure 64).
10. Remove the clutch cable and disconnect the clutch ca-
ble from the lever (12, Figure 64).
11. On 1994-1996 models, remove the screw (7, Figure
64) and anti-rattle spring (5) from the bottom of the clutch
lever.
12. Note the cable routing before removing it. The new ca-
ble must be routed along the same path. Slide the clutch ca-
ble through the guide clip (Figure 65) and remove the
clutch cable.
13. Slide the O-ring over the lower cable end fitting (Fig-
ure 63) and insert the cable into the primary drive cover.
Turn the cable (Figure 62) clockwise and tighten it se-
curely.

282

CHAPTER SEVEN

CLUTCH RELEASE MECHANISM (1994-2003 MODELS)

1. Screw and

washer

2. Clutch spring

cover

3. Spring
4. Lockplate
5. Nut
6. Coupling

(1994-1996
models)

7. Outer ramp
8. Ball (3)
9. Coupling

(1997-2003
models)

10. Inner ramp
11. Quad ring
12. Snap ring
13. Primary drive

cover

14. Clutch adjusting

screw assembly

15. Clutch cable
16. O-ring

14A. On 1994-1996 models, fit the coupling over the clutch
cable with the rounded side facing out and the ramp con-
nector button facing in.
14B. On 1997-2003 models, fit the coupling over the
clutch cable with the rounded side facing in and the ramp
connector button facing out. With the retaining side of the
ramp facing in, install the ramp hook around the coupling
button. Then rotate the assembly counterclockwise until
the tang on the inner ramp fits into the primary drive cover
slot.
15. Thread the nut onto the clutch adjusting screw until
the slot in the end of the screw is accessible with a screw-
driver. Then align and install the hex portion on the nut
into the outer ramp recess. Turn the clutch adjusting screw
counterclockwise until resistance is felt, then backoff 1/4
turn.

16. Adjust the clutch as described in Chapter Three. The
spring and lockplate shown in Figure 67 will be installed
during the clutch adjustment procedure.

17. Route the clutch cable as shown in Figure 66.

18. Install the anti-rattle spring (6, Figure 64) and screw
(7) onto the clutch lever (12).

19. Connect the clutch cable to the clutch lever and secure
it with the clutch cable pin (5, Figure 64).

20. Install the clutch lever into the bracket.

21. Apply a small amount of anti-seize compound to the
pivot pin shoulder. Then install the pivot pin through the
clutch bracket and lever and secure it with the snap ring (4,
Figure 64).

22. Adjust the clutch (Chapter Three).

PRIMARY DRIVE AND CLUTCH (1991-2003 MODELS)

283

Table 1 CLUTCH SPECIFICATIONS

New

Service limit

in. (mm)

Friction plates

Thickness

Individual plates

0.0835-0.0897

–

(2.121-2.278)

–

Friction plate pack*

–

0.6610
(16.79)

Steel plate thickness

0.0609-0.0649

–

(1.547-1.648)

Warp (all plates)

–

0.006
(0.15)

*Refer to text for measurement procedure.

Table 2 CLUTCH TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N.m

Chain tensioner stud nut

20-25

–

27-34

Clutch cable housing fitting

–

36-60

4-7

Clutch lever clamp bolts

–

60-80

7-9

Clutch nut*

70-80

–

95-108

Clutch release mechanism

screws

22-40

–

2.5-4.5

Engine sprocket nut*

1991-1997 models

150-165

–

203-224

1998-2003 models

190-210

–

258-285

Inspection cover screws

–

40-60

5-7

Primary chain adjuster locknuts

Upper

–

120-144

14-16

Lower

20-25

–

27-34

Primary drive cover

mounting screws

–

80-110

9-12

Shift lever pinch bolt

–

80-110

9-12

Shift rod bolt

–

Transmission drain plug

14-21

–

19-28

*Apply threadlock (Loctite 262 or equivalent).

CHAPTER EIGHT

FOUR-SPEED TRANSMISSION

(1986-1990 MODELS)

This chapter covers the four-speed transmission, internal

gearshift assemblies and shift mechanism. Tables 1-8 are at
the end of this chapter.

When the clutch is engaged, the mainshaft is driven by

the clutch hub, which is driven by the primary chain
sprocket/clutch outer housing. Power flows from the
mainshaft through the selected gear combination to the
countershaft, which drives the main drive gear and trans-
mission sprocket.

To gain access to the transmission and internal shift

mechanism, it is not necessary to remove the engine or dis-
assemble the crankcase. The transmission components are
contained behind an access door on the left crankcase half.

TRANSMISSION

Transmission Removal

1. Drain the transmission/primary drive oil (Chapter
Three).
2. Remove the clutch and primary chain (Chapter Six).
3. Remove the drive sprocket (Chapter Thirteen).
4. Remove the stator (Chapter Twelve).
5. Remove the thrust washer (Figure 1).
6. Remove the transmission access cover bolts. See Figure 2.
7. Remove the access cover (Figure 2) with the transmis-
sion and shift mechanism assembly attached. See Figure 3.

8. Remove the shift lever (Figure 4).

Transmission Installation

1. Install the shift shaft into the crankcase so that the shift
lever arm is centered as shown in Figure 5.

NOTE

Mark the shift shaft at the 12 o’clock position
as shown in

Figure 6

. Marking the shaft pro-

vides a reference mark to determine if the shift
lever arm position changes when installing
the transmission.

2. Install the transmission access cover (Figure 3). Then
rotate the countershaft to check the shift shaft is engaged
with the shifter pawl. To do so, lightly rotate the shift shaft.
A noticeable resistance to movement indicates proper
engagement.
3. Install the access cover bolts (Figure 2). The short bolt
must be installed in the upper right hole. Tighten all access
cover bolts to 14-19 ft.-lb. (19-26 N•m).

CAUTION

Do not use the old stator Torx screws. New
Torx screws have a pellet formed locking
compound on their threads. When new Torx
screws are installed, the pellet breaks and

releases the locking compound on the bolt
threads. The locking compound on the old
bolts cannot be reused; if installed, the old
bolts may loosen during engine operation.

4. Install the alternator stator as described in Chapter
Twelve.
5. Install the clutch (Chapter Six).
6. Install the drive sprocket (Chapter Thirteen).
7. Install the rear chain. Adjust it as described in Chapter
Three.
8. Refill the transmission/primary oil (Chapter Three).

Transmission Disassembly

Refer to Figure 7.

1. Pull the mainshaft assembly (Figure 8) from the clutch
gear.
2. Remove the following from the countershaft:

a. First gear washer (Figure 9).
b. First gear (Figure 10).
c. Third gear washer (Figure 11).

3. Remove the shift fork shaft (Figure 12).
4. Remove the shift fork (Figure 13) from the countershaft
third gear.
5. Remove the finger rollers (Figure 14) from the shift fork.
6. Remove countershaft third gear (Figure 15).
7. Remove mainshaft second gear (Figure 16).

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

285

Access cover

Bolt

Three bolts

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 22