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Harley Davidson 2004 Touring Models. Service Manual - page 45

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11. See Figure 5-12. Check for a GROUNDED ARMATURE

13. See Figure 5-14. Check for GROUNDED FIELD WIND-

with an ohmmeter or continuity tester. Touch one probe

ING with an ohmmeter or continuity tester. Touch one

to any commutator segment, and the other probe to the

probe to the frame, and the other probe to each of the

armature core. There should be no continuity (infinite

brushes attached to the field winding. There should be

ohms). If there is any continuity the armature is

no continuity (infinite ohms). If there is any continuity at

grounded and should be replaced.

either brush, the field winding(s) are grounded and the

field frame should be replaced.

Figure 5-12. Grounded Armature Test

Figure 5-14. Grounded Field Test

12. See Figure 5-13. Check for OPEN ARMATURE with an

14. See Figure 5-15. Check for OPEN FIELD WINDING with

ohmmeter or continuity tester. Check for continuity

an ohmmeter or continuity tester. Touch one probe to the

between all commutator segments. There should be

field wire, and the other probe to each of the brushes

continuity (0 ohms) at all test points. No continuity at any

attached to the field coils. There should be continuity. If

test point indicates armature is open and should be

there is no continuity at either brush, the field winding(s)

replaced.

are open and the field frame should be replaced.

Figure 5-13. Armature Open Test

Figure 5-15. Open Field Test

5-10

2004 Touring: Starter

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15. See Figure 5-16. Test BRUSH HOLDER INSULATION

with an ohmmeter or continuity tester. Touch one probe

f1540a5x

to holder plate and the other probe to each of the posi-

tive (insulated) brush holders. There should be no conti-

nuity (infinite ohms). If there is continuity at either brush

holder, the brush holder assembly should be replaced.

Touch one probe to the non-insulated brush holders and

the other probe to the holder plate. If you measure any

resistance, the brush holder must be replaced.

f1541x5x

Figure 5-18. Drive Housing Assembly

Figure 5-16. Brush Holder Insulation Test

16. Check armature bearings (10) and replace if necessary.

3506

See Figure 5-4.

NOTE

Spring (21) and ball (22) are loose in shaft gear end. See

Figure 5-4.

Figure 5-19. Clutch Assembly

17. See Figures 5-4, 5-17 and 5-18. Remove the two drive

housing mounting screws

(11) and washers

(12).

Remove drive housing (13) from solenoid housing (14).

18. See Figures 5-4 and 5-19. Remove drive (15), idler gear

(16) and idler gear bearing (17) from drive housing (13).

O-ring (18) is in groove in drive housing.

19. Remove spring (19) and shaft (20).

f1557x5x

Figure 5-17. Remove Drive Housing

2004 Touring: Starter

5-11

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STARTER SOLENOID

5.5

2.

Remove cover and gasket. Discard gasket.

GENERAL

3.

Plunger can now be removed from solenoid housing.

The starter solenoid is a switch designed to open and close

the starting circuit electromagnetically. The switch consists of

contacts and a winding around a hollow cylinder containing a

movable plunger. When the winding is energized by the bat-

ASSEMBLY

tery, the magnetism produced pulls the plunger into the coil.

The plunger moves against two main switch contacts, closing

the circuit.

1.

Replace wire connection hardware as necessary.

2.

Apply a light coat of Lubriplate® 110 to plunger shaft.

DISASSEMBLY

Install plunger in solenoid housing.

1. See Figure 5-20. Remove screws and washers. Clip

3.

Install new gasket. Place cover in position and install

comes off with screw.

screws, washers and clip.

Cover

Clip

Gasket

Screw and

Washer

Plunger

Solenoid

Housing

CAUTION

Do not tighten the inside nut without

removing other items shown. Movement

will cause damage to the contact.

f1079axx

Figure 5-20. Starter Solenoid

5-13

2004 Touring: Starter

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STARTER JACKSHAFT

5.6

REMOVAL/DISASSEMBLY

1.

Remove seat. See Section 2.24 SEAT, REMOVAL.

7945

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.

2.

Unthread bolt and remove battery negative cable (black)

from battery negative (-) terminal.

3.

See Figure 5-21. Remove the primary chaincase cover.

Remove the clutch assembly, primary chain and com-

pensating sprocket components as a single assembly.

See Section 6.5 PRIMARY CHAINCASE, REMOVAL,

steps 3-15.

Starter

Jackshaft

NOTE

Assembly

If only the jackshaft bolt, thrust washer, lockplate, pinion gear

and/or spring require servicing, then the primary chain and

Figure 5-21. Primary Chaincase

clutch assembly may be left in place.

Retaining

Ring

f1211c5x

Keyway

Output

Coupling

Shaft

Coupling

Counterbore

Spring

Jackshaft

Slot

Key

Retaining

Ring

Primary Chaincase

Jackshaft

Bushing

Pinion

Bolt

Gear

Primary

Cover Bushing

Tab

Thrust

Washer

Lockplate

Figure 5-22. Starter Jackshaft Assembly

2004 Touring: Starter

5-14

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SPECIFICATIONS

6.1

OVERALL GEAR RATIOS

SPROCKETS

Overall gear ratios indicate the number of engine revolutions

required to drive the rear wheel one revolution.

Number of Teeth

Sprocket

All Models

Gear

All Models

Engine

25

1

10.11

Clutch

36

2

6.96

Transmission

32

3

4.95

Rear wheel

70

4

3.86

5

3.15

CLUTCH

CHAINS AND BELTS

Clutch

Description

Type

Wet-multiple disc

Primary Chain Adjustments

1/16-1/8 in.

Clutch lever free play

1.6-3.2 mm

Free Play

Inches

Millimeters

loosen 1/2-1 turn after

Clutch screw adjustment

lightly seating

COLD Engine

5/8-7/8 inch

15.9-22.2 mm

HOT Engine

3/8-5/8 inch

9.5-15.9 mm

TORQUE VALUES

Primary Chaincase Lubricant

Item

ft/in-lbs

Nm

Primary chain tensioner

Ounces

Milliliters

21-29 ft-lbs

29-39 Nm

shoe nut

Amount

32

946

Tensioner shoe adjuster

12-14 ft-lbs

16-19 Nm

plate screws

Quart

Gallon

Primary chain inspection

84-108 in-lbs

10-12 Nm

Part Number

cover screws

99887-84

99886-84

Clutch adjuster screw

72-120 in-lbs

8-14 Nm

locknut

Rear Belt Adjustment

Clutch inspection cover

84-108 in-lbs

10-12 Nm

screws

Deflection

Inches

Millimeters

Clutch diaphragm spring

90-110 in-lbs

10-12 Nm

retainer to clutch hub bolts

On Jiffy Stand Without

Rear axle cone nut

95-105 ft-lbs

129-142 Nm

Rider or Luggage

1/4 - 5/16

6.4

- 7.9

Rear swingarm pivot

10 psi (69 kPa)

at 10 lbs force

at 4.5 kg force

40-45 ft-lbs

54-61 Nm

shaft locknut

in Rear Shocks

Rear swingarm bracket

Motorcycle Upright

34-42 ft-lbs

46-57 Nm

3/16 - 1/4

4.8

- 6.4

bolts

With Rear Wheel

at 10 lbs force

at 4.5 kg force

Continued ...

in the Air

2004 Touring: Drive

6-1

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TORQUE VALUES (CONT.’D)

Item

ft/in-lbs

Nm

Shock bottom

35-40 ft-lbs

47-54 Nm

mounting bolt

Exhaust pipe TORCA

45-60 ft-lbs

61-81 Nm

clamps

Heat shield worm drive

20-40 in-lbs

2.3-4.5 Nm

clamp screws

Transmission mainshaft

60 ft-lbs, then

81 Nm, then

sprocket nut

35° to 45°

35° to 45°

Mainshaft sprocket nut

lockplate socket head

90-110 in-lbs

10-12 Nm

screws

Rear wheel sprocket bolts

55-65 ft-lbs

75-88 Nm

Primary chaincase to

crankcase and transmis-

18-21 ft-lbs

24-28 Nm

sion

Front and rear starter

13-20 ft-lbs

18-27 Nm

mounting screws

Starter jackshaft bolt

60-80 in-lbs

6.8-9.0 Nm

Engine compensating

150-165 ft-lbs

203-224 Nm

sprocket nut

Clutch hub mainshaft nut

70-80 ft-lbs

95-108 Nm

Primary chaincase cover

84-108 in-lbs

9-12 Nm

allen head socket screws

Primary chaincase drain

36-60 in-lbs

4.1-6.8 Nm

plug

Passenger footboard

15-18 ft-lbs

20-24 Nm

socket screws

1/4”

90-110 in-lbs

10.2-12.4 Nm

Shifter lever

socket screws

5/16”

18-22 ft-lbs

24-30 Nm

6-2

2004 Touring: Drive

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PRIMARY CHAIN AND SPROCKETS

6.2

PRIMARY CHAIN ADJUSTMENT

f1840x6x

Top Center Nut

At the 1000 mile (1600 km) service interval, and at every

5000 mile (8000 km) service interval thereafter, inspect the

primary chain tension. Proceed as follows:

1. See Figure 6-1. Using a T27 TORX drive head, remove

four screws to free the primary chain inspection cover

Primary

from the primary chaincase cover.

Chain

2. Check the primary chain tension. Push on the upper

strand to verify that it has free up and down movement

midway between the engine compensating sprocket

(front) and the clutch sprocket (rear).

3. Measure the free play to be sure that it falls within the

ranges specified for a hot or cold engine:

Adjuster Shoe

Retaining

Table 6-1. Primary Chain Adjustment

Narrow End Forward

Ring

(Free Play)

Inches

Millimeters

Figure 6-2. Chain Tensioner Assembly

COLD ENGINE

5/8-7/8 inch

15.9-22.2 mm

NOTE

HOT ENGINE

3/8-5/8 inch

9.5-15.9 mm

As chains stretch and wear, they run tighter at one spot than

another. Always adjust the free play at the tightest spot in the

4. If the chain is too tight or too loose, then adjust as fol-

chain. Replace the primary chain if it is worn to the point

lows:

where it cannot be properly adjusted.

a. Locate the chain tensioner assembly and loosen the

CAUTION

top center nut a maximum of two turns. See Figure

6-2.

Always keep the primary chain properly adjusted. Allow-

ing the chain to run too tight or too loose will result in

b. Raise or lower the chain tensioner assembly as

excessive chain and sprocket wear.

necessary to obtain the specified free play.

c. Tighten the top center nut of the chain tensioner

assembly to 21-29 ft-lbs (29-39 Nm).

f1210x6x

5. Align holes in new gasket with holes in the primary

chaincase cover. Using a T27 TORX drive head, install

four screws to secure primary chain inspection cover to

primary chaincase cover. Alternately tighten screws to

1

84-108 in-lbs (10-12 Nm) in a crosswise pattern. See

1

4

Clutch

3

Figure 6-1.

4

Inspection

Cover

Primary

Chain

Inspection

2

5

Cover

ADJUSTER SHOE REPLACEMENT

2

3

If the nylon adjuster shoe is worn or damaged, replace as fol-

lows:

1. Remove the primary chaincase cover. See Section 6.5

Figure 6-1. Primary Chaincase Cover

PRIMARY CHAINCASE, REMOVAL, steps 1-8.

2004 Touring: Drive

6-3

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f1096dxd

6

1

3

5

4

2

1.

Sprocket Nut

6. Alternator Rotor Spacer-

7.

Alternator Rotor

2.

Sprocket Cover

Low Output Rotor Only

8.

Sprocket Shaft Spacer

3.

Sliding Cam

0.020 inch (0.508 mm)

9.

Engine Sprocket Shaft

4.

Compensating Sprocket

5.

Shaft Extension

EXPLODED VIEW

4

3

2

NOTE

Alternator stator, oil seal and left

crankcase not shown.

1

5

9

8

6

CROSS SECTIONAL VIEW

7

Figure 6-3. Engine Compensating Sprocket Components

2.

Loosen top center nut from captured bolt of chain ten-

3. Lower the chain tensioner assembly until the adjuster

sioner assembly. See Figure 6-2.

shoe just contacts the inner primary housing.

6-4

2004 Touring: Drive

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1WARNING

Measure at Compensating Sprocket

A

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.

4.

Remove retaining ring from nub and pull adjuster shoe

from chain tensioner. Discard adjuster shoe and retain-

ing ring.

5. Slide new adjuster shoe onto chain tensioner. Be sure

Dial Vernier

Caliper

that the narrow end of the shoe is at the front, the wider

end at the rear.

1WARNING

Straightedge

Always wear proper eye protection when installing re-

7949

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

Measure at Clutch Sprocket

B

cause eye injury.

6.

To lock position of adjuster shoe, install new retaining

ring onto nub of chain tensioner. Verify that retaining ring

is fully seated in the groove.

7.

Raise or lower the chain tensioner assembly as neces-

sary to obtain the specified free play. See PRIMARY

CHAIN ADJUSTMENT, steps 2-4.

8.

Tighten the top center nut of the chain tensioner assem-

bly to 21-29 ft-lbs (29-39 Nm).

9. Install the primary chaincase cover. See Section 6.5

PRIMARY CHAINCASE, INSTALLATION, steps 20-31.

7947

DISASSEMBLY

Figure 6-4. Check Sprocket Alignment

See Section 6.5 PRIMARY CHAINCASE, REMOVAL, steps

Sprocket Alignment (Figure 6-3, 6-4)

1-16.

The engine compensating sprocket is aligned with the clutch

sprocket by a spacer installed between the alternator rotor

CLEANING AND INSPECTION

and shaft extension (low output rotor only). Reinstall the

same thickness spacer removed or determine the correct

1. Periodically inspect the primary chain for cracked, bro-

spacer size as follows:

ken or badly worn links. Replace as necessary.

1. With the primary chaincase cover removed, verify that

2. Inspect compensating sprocket components for damage

the primary chain tension is properly adjusted. See PRI-

or wear. Replace parts as necessary.

MARY CHAIN ADJUSTMENT in this section.

3. Inspect clutch sprocket for damage or wear. If broken or

2. At both the engine compensating sprocket and clutch

damaged teeth are found, the clutch shell and sprocket

sprocket sides, push the primary chain inward as far as it

assembly must be replaced.

will go.

2004 Touring: Drive

6-5

HOME

3.

Place a straightedge vertically across the flanges (cover

ASSEMBLY

gasket surface) near the engine compensating sprocket.

4.

Using a dial vernier caliper, measure the distance from

See Section

6.5 PRIMARY CHAINCASE, INSTALLATION,

the straightedge to the chain link sideplate. Measure as

steps 8-31.

close to the engine compensating sprocket as possible

and record the measurement. See A of Figure 6-4.

5.

Repeat the measurement on the clutch sprocket side.

See B of Figure 6-4.

For proper primary chain alignment, the difference

between the two measurements must not exceed 0.030

inch (0.76 mm). If the measurement is not within specifi-

cation, install the appropriate variable thickness spacer

on the engine sprocket shaft between the alternator rotor

and shaft extension. See the adjacent table for the vari-

ous spacer thicknesses.

Table 6-2. Alternator Rotor Spacers

Inches

Millimeters

Part Number

0.010

0.25

35850-84

0.020

0.51

35851-84

0.030

0.76

35852-84

0.060

1.52

24032-70

0.090

2.29

24033-70

0.120

3.05

24034-70

0.150

3.81

24035-70

0.180

4.57

24036-70

0.210

5.33

24037-70

6-6

2004 Touring: Drive

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CLUTCH

6.3

ADJUSTMENT

f1440x6x

Jam

Nut

CAUTION

Rubber

Perform the clutch adjustment with the motorcycle at

Boot

room temperature. The clearance at the adjuster screw

will increase as the power train temperature increases. If

Cable

adjuster screw is adjusted while the powertrain is hot,

End

clearance at push rod bearing could be insufficient with

power train cold and clutch slippage could occur.

Cable

Adjuster

Adjust the clutch at the 1000 mile (1600 km) service interval,

and at every 5000 mile (8000 km) service interval thereafter.

Figure 6-6. Clutch Cable Adjuster Mechanism

NOTE

Also perform adjustment procedure whenever any clutch

components are replaced. Then repeat adjustment after first

Adjust for 1/16-1/8 inch

500 miles (800 km) of use.

(1.6-3.2 mm) gap

between ferrule

Clutch

and bracket

1. Stand motorcycle upright and level.

Cable

Ferrule

Clutch Lever

Bracket

Adjuster

f1421x6x

Screw

Figure 6-7. Adjust Clutch Free Play

2.

Using a T27 TORX drive head, remove five screws (with

captive washers) to free clutch inspection cover from pri-

Locknut

mary chaincase cover.

3.

See Figure 6-6. Slide rubber boot off cable adjuster.

Holding cable adjuster with 1/2 inch wrench, loosen jam

Release

nut using a 9/16 inch wrench. Back jam nut away from

Plate

cable adjuster. Move adjuster toward jam nut to intro-

Retaining

Ring

duce a large amount of free play at hand lever.

4.

See Figure 6-5. Loosen locknut on clutch adjuster screw.

To take up all free play in push rods, turn screw inward

(clockwise) until lightly seated.

5.

Back out adjuster screw 1/2 to 1 turn. While holding

adjuster screw with an allen wrench, tighten locknut to

f1509b6x

72-120 in-lbs (8-14 Nm).

6.

Squeeze clutch lever to maximum limit three times to set

Figure 6-5. Clutch Adjustment

ball and ramp release mechanism.

2004 Touring: Drive

6-7

HOME

7. Turn cable adjuster away from jam nut until slack is elim-

inated at hand lever. Pull clutch cable ferrule away from

f1523x6x

Damper

Clutch

clutch lever bracket to check free play. Turn cable

Spring

Hub

adjuster as necessary to obtain 1/16 to 1/8 inch (1.6-3.2

Clutch

mm) free play between end of cable ferrule and clutch

Shell

lever bracket, as shown in Figure 6-7.

Steel Plate

8.

Hold adjuster with 1/2 inch wrench. Using 9/16 inch

wrench, tighten jam nut against cable adjuster. Cover

cable adjuster mechanism with rubber boot.

9.

Remove quad ring from groove in primary chaincase

cover. Wipe all lubricant from the quad ring and inspect

for cuts, tears or signs of deterioration. Replace as nec-

essary.

10. Swab all lubricant from the quad ring groove. Install

quad ring in primary chaincase cover with the nubs con-

Damper

Narrow

tacting the ring groove walls.

Spring Seat

Friction Plate

NOTE

If lubricant is not thoroughly removed from both the quad ring

and groove, compression of the ring during installation of the

Figure 6-8. Clutch Pack Stack-Up (Cut-Away View)

clutch inspection cover can cause lubricant to be squeezed

to the outboard side of the ring groove, resulting in some

temporary weepage around the inspection cover.

4.

Remove friction plates, steel plates, damper spring and

damper spring seat from clutch hub.

11. Using a T27 TORX drive head, install five screws (with

captive washers) to secure clutch inspection cover to the

5.

See CLEANING AND INSPECTION in this section.

primary chaincase cover. Alternately tighten screws to

84-108 in-lbs (10-12 Nm) in the pattern shown in Figure

ASSEMBLY

6-1.

CLUTCH PACK ONLY

1.

Submerge and soak all friction and steel plates in PRI-

REMOVAL/INSTALLATION

MARY CHAINCASE LUBRICANT for at least five min-

utes.

To remove the clutch without disassembly, see Section 6.5

2.

Install the narrow friction plate on the clutch hub engag-

PRIMARY CHAINCASE, REMOVAL, steps 1-16.

ing tabs on plate with slots in clutch shell.

For installation instructions, see Section

6.5 PRIMARY

3.

Install damper spring seat on clutch hub so that it seats

CHAINCASE, INSTALLATION, steps 8-31.

inboard of narrow friction plate.

NOTE

4.

Install damper spring on clutch hub with the concave

side up (facing opposite damper spring seat). See Fig-

If only the clutch pack is to be disassembled, see PARTIAL

ure 6-8.

DISASSEMBLY below, a procedure that can be performed on

the motorcycle without removing the clutch shell or hub.

5.

Install a steel plate and then a friction plate on the clutch

hub. Install seven remaining sets in the same manner,

For complete disassembly of the clutch, which includes

alternating between steel plates and friction plates.

clutch pack disassembly and bearing replacement, see

6.

Install pressure plate on clutch hub aligning holes in

COMPLETE DISASSEMBLY.

plate with threaded bosses on hub.

7.

Seat diaphragm spring in recess of pressure plate with

PARTIAL DISASSEMBLY

the concave side down.

8.

Align holes in diaphragm spring retainer with threaded

CLUTCH PACK ONLY

bosses on clutch hub. Tabs on spring retainer contact

1. Remove the primary chaincase cover. See Section 6.5

flats on inboard side of bosses.

PRIMARY CHAINCASE, REMOVAL, steps 1-8.

9.

Install six bolts to secure diaphragm spring retainer to

2. Remove six bolts to release diaphragm spring retainer

clutch hub. Alternately tighten bolts to

90-110 in-lbs

from clutch hub. See Figure 6-9.

(10.2-12.4 Nm).

3. Remove diaphragm spring retainer, diaphragm spring

10.

Install the primary chaincase cover. See Section 6.5

and pressure plate from clutch hub.

PRIMARY CHAINCASE, INSTALLATION, steps 20-31.

6-8

2004 Touring: Drive

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f1514x6x

5

6

4

2

3

7

8

1

9

10

11

17

16

14

18

15

19

12

23

20

13

21

1. Retaining Ring

24

2. Clutch Shell

22

3. Bearing

10. Damper Spring

4. Retaining Ring

11. Damper Spring Seat

5. Clutch Hub

12. Pressure Plate

17. Retaining Ring

6. Mainshaft Nut

13. Diaphragm Spring

18. Locknut

7. Friction Plate (9)

14. Diaphragm Spring Retainer

19. Adjuster Screw

22. Thrust Washer (2)

8. Steel Plate (8)

15. Bolt (6)

20. Push Rod

23. Throw Out Bearing

9. Narrow Friction Plate

16. Release Plate

21. Oil Slinger

24. Retaining Ring

Figure 6-9. Clutch Assembly

2004 Touring: Drive

6-9

HOME

CLEANING AND INSPECTION

Remove retaining ring from clutch hub.

1.

Wash all parts in cleaning solvent, except for friction

plates and bearing, if removed. Blow dry with com-

pressed air.

2.

Check friction plates as follows:

● Wipe all lubricant from the friction plates. Measure

the thickness of each plate with a dial caliper or

micrometer. If the thickness of any plate is less than

0.143 inch (3.62 mm), discard the friction plates and

replace with an entirely new set.

● Look for worn or damaged fiber surface material

(both sides).

NOTE

Replace all nine friction plates with an entirely new set if any

individual plate shows evidence of wear or damage.

f1519x6x

3. Check steel plates as follows:

Press clutch hub from bearing.

● Discard any plate that is grooved or bluish in color.

Blue plates are likely warped or distorted.

● Check each plate for distortion. Lay the plate on a

precision flat surface. Insert a feeler gauge between

the plate and the flat surface in several places.

Replace any steel plate that is warped more than

0.006 inch (0.15 mm).

4. See Figure 6-9. Holding the clutch hub, rotate the clutch

shell to check bearing for smoothness. Replace the

bearing if it runs rough or binds.

5. Check the primary chain sprocket and the starter ring

gear on the clutch shell. Replace the clutch shell if either

sprocket or ring gear are badly worn or damaged.

6. Check the slots that mate with the clutch plates on both

the clutch shell and hub. Replace shell or hub if slots are

worn or damaged.

7. Check the diaphragm spring and diaphragm spring

retainer for cracks or bent tabs. Obtain a new diaphragm

spring or diaphragm spring retainer if either condition

f1522x6x

exists.

Figure 6-10. Remove Clutch Hub from Clutch Shell

COMPLETE DISASSEMBLY

4.

Remove friction plates, steel plates, damper spring and

CLUTCH PACK AND BEARING

damper spring seat from clutch hub.

1. Remove clutch assembly from the motorcycle. See Sec-

tion 6.5 PRIMARY CHAINCASE, REMOVAL, steps 1-16.

CAUTION

2. Remove six bolts to release diaphragm spring retainer

To avoid possible bearing damage, do not disassemble

from clutch hub. See Figure 6-9.

the clutch shell and hub assembly unless the bearing,

3. Remove diaphragm spring retainer, diaphragm spring

hub or shell require replacement. Replace the bearing if

and pressure plate from clutch hub.

disassembled.

6-10

2004 Touring: Drive

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6.

Supporting clutch shell in same orientation, use arbor

press and a suitable press plug to press hub from bear-

Remove retaining ring from clutch shell.

ing in clutch shell. See lower frame of Figure 6-10.

7.

Turn clutch shell over so that the sprocket side is down.

Remove retaining ring from groove in clutch shell bore.

See upper frame of Figure 6-11.

8.

Turn clutch shell over so that sprocket side is up. Using

arbor press and a suitable press plug, press on inner

race to remove bearing from clutch shell bore. See lower

frame of Figure 6-11.

9.

See CLEANING AND INSPECTION in this section.

ASSEMBLY

CLUTCH PACK AND BEARING

1.

Orient clutch shell in arbor press with sprocket side

f1521x6x

down. Be sure to support clutch shell bore on sprocket

side. Using a suitable press plug, press against outer

Press bearing from clutch shell.

race until bearing contacts shoulder in clutch shell bore.

1WARNING

Always wear proper eye protection when installing re-

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

worn. Slippage may propel the ring with enough force to

cause eye injury.

NOTE

Note that one side of the retaining ring is beveled. Always

install the ring with the beveled side opposite the bearing.

2.

Install retaining ring in groove of clutch shell bore, so

that the flat side of the ring is in towards the bearing, the

beveled side out.

3.

Center hub in bearing. Be sure that bearing inner race is

supported with sleeve on sprocket side. Press hub into

bearing until hub shoulder contacts bearing inner race.

4.

Turn assembly over so that the sprocket side is up.

Install retaining ring in groove of clutch hub.

f1520x6x

5.

Place clutch assembly on bench oriented with the

sprocket side down.

Figure 6-11. Remove Bearing from Clutch Shell

6.

Submerge and soak all friction and steel plates in PRI-

MARY CHAINCASE LUBRICANT for at least five min-

utes.

1WARNING

7.

Install the narrow friction plate on the clutch hub engag-

Always wear proper eye protection when removing re-

ing tabs on plate with slots in clutch shell. See Figure 6-

taining rings. Use the correct retaining ring pliers. Verify

12.

that the tips of the pliers are not damaged or excessively

8.

Install damper spring seat on clutch hub so that it seats

worn. Slippage may propel the ring with enough force to

inboard of narrow friction plate.

cause eye injury.

9.

Install damper spring on clutch hub with the concave

5.

With the sprocket side up, remove retaining ring from

side up (facing opposite damper spring seat). See Fig-

clutch hub groove. See upper frame of Figure 6-10.

ure 6-8.

2004 Touring: Drive

6-11

HOME

12. Seat diaphragm spring in recess of pressure plate with

Narrow Plate

the concave side down.

13. Align holes in diaphragm spring retainer with threaded

bosses on clutch hub. Tabs on spring retainer contact

flats on inboard side of bosses.

14. Install six bolts to secure diaphragm spring retainer to

clutch hub. Alternately tighten bolts to

90-110 in-lbs

(10.2-12.4 Nm).

15. Install clutch assembly on motorcycle. See Section 6.5

PRIMARY CHAINCASE, INSTALLATION, steps 8-31.

Regular Plate

f1513x6x

Figure 6-12. Friction Plates

10. Install a steel plate and then a friction plate on the clutch

hub. Install seven remaining sets in the same manner,

alternating between steel plates and friction plates.

11. Install pressure plate on clutch hub aligning holes in

plate with threaded bosses on hub.

6-12

2004 Touring: Drive

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SECONDARY DRIVE BELT AND SPROCKETS

6.4

ADJUSTMENT

Transmission

Rear Wheel

Sprocket

Sprocket

1.

Remove left side saddlebag. See Section 2.25 SAD-

DLEBAG, REMOVAL.

2.

Check deflection at the loosest spot in the belt with the

transmission in neutral and the motorcycle cold. Use

BELT TENSION GAUGE (HD-35381A), or install narrow

saddle (HD-35381-3) on existing gauge, and apply 10

lbs. (4.5 kg) of force at the midpoint of the bottom belt

10 lbs. (4.5 kg)

strand. See Figure 6-13. Belt deflection should be as fol-

of Force

lows:

See Table 6-3.

f1652x6x

Table 6-3. Belt Deflection

Orientation

Inches

Millimeters

Figure 6-13. Check and Adjust Belt Deflection

On Jiffy Stand

Without Rider or Luggage

1/4 - 5/16

6.4

- 7.9

b. Using a bungee cord, tie the muffler to the lower

10 psi (69 kPa) in Rear Shocks

saddlebag support rail.

Motorcycle Upright

3/16 - 1/4

4.8

- 6.4

With Rear Wheel in the Air

c. Loosen TORCA clamp between rear header pipe

and muffer.

If belt deflection is within specification, install left side

d. Remove two bolts (with lockwashers) to detach muf-

saddlebag. If adjustment is necessary, proceed to step

fler from the lower saddlebag support rail.

3.

e. Remove bungee cord to release muffler from lower

3.

Remove right side saddlebag. See Section 2.25 SAD-

saddlebag support rail.

DLEBAG, REMOVAL.

4.

Remove right side muffler as follows:

5.

Standing on right side of motorcycle, remove E-clip from

a. Open worm drive clamps to remove heat shield

groove at end of axle. Loosen cone nut, and then snug

from rear header pipe in front of muffler.

to 15-20 ft-lbs (20-27 Nm). See Figure 6-14.

LEFT SIDE

RIGHT SIDE

Increase

Reduce

Belt

Belt

Deflection

Deflection

Cone

Nut

Weld

Nub

Weld

Weld

Nut

E-Clip

Nub

Adjuster

8398

8407

Cam

Figure 6-14. Move Rear Wheel Forward Until Adjuster Cams Just Contact Weld Nubs

2004 Touring: Drive

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