Harley Davidson 2009 Dyna Models. Service manual - page 29

CHAINCASE COVER, Removal

Figure 5-30

. Remove six bolts (1) (metric) to release

diaphragm spring retainer (2) from clutch hub. Loosen
each bolt gradually and in a star sequence around the
hub.

Remove diaphragm spring retainer, diaphragm spring (3)
and pressure plate (4) from clutch hub.

Remove friction plates (5, 7), steel plates (6), damper
spring (8) and damper spring seat (9) from clutch hub (11).
Continue with Cleaning And Inspection.

Cleaning And Inspection

Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)

Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Blow parts dry with low pressure
compressed air.

Check friction plates as follows:

Blow off all lubricant from the friction plates. Do not
wipe off with a rag.

Measure the thickness of each plate with a dial caliper
or micrometer.

If the thickness of any plate is less than 0.143 in. (3.62
mm), discard all 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. Submerge
and soak all friction plates in FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-
05, qt.) for at least five minutes.

Check the steel plates as follows:

Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.

Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 in. (0.15 mm).

Holding the clutch hub, rotate the clutch shell to check
bearing for smoothness. Replace the bearing if it runs
rough, binds or has any end play.

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.

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.

Check the diaphragm spring and diaphragm spring retainer
for cracks or bent tabs. Obtain a new diaphragm spring
or diaphragm spring retainer if either condition exists.

5-14 2009 Dyna Service: Drive

sm02704a

Damper spring seat

Bolt (6) (metric)

10.

Diaphragm spring retainer

Mainshaft nut (metric)

11.

Clutch hub

Diaphragm spring

12.

Pressure plate

Retaining ring

13.

Bearing

Friction plate (9)

14.

Steel plate (8)

Clucth shell

15.

Retaining ring

Narrow friction plate

Damper spring

Figure 5-30. Clutch Shell Assembly

2009 Dyna Service: Drive 5-15

Assembly

NOTE

Submerge and soak all friction plates in FORMULA+ TRANS-
MISSION AND PRIMARY CHAINCASE LUBRICANT (Part No.
99851-05, qt.) for at least five minutes.

See

Figure 5-31

. Install the narrow friction plate on the

clutch hub. Engage tabs on plate with slots in clutch shell.

5.3 PRIMARY CHAINCASE COVER, Installation

Figure 5-30

. Install damper spring seat (9) on clutch

hub (11). It must sit inboard of narrow friction plate (7).

NOTE

See

Figure 5-36

. Notice damper spring (4) orientation with

respect to damper spring seat (3).

See

Figure 5-30

. Install damper spring (8) on clutch hub

with the concave side out (facing away from damper spring
seat).

Install a steel plate (6) with round edge outward and then
a friction plate (5) on the clutch hub. Install seven
remaining sets in the same manner, alternating between
steel plates and friction plates.

Install pressure plate (4) on clutch hub aligning holes in
plate with threaded bosses on hub.

Seat diaphragm spring (3) in recess of pressure plate with
the concave side inward.

Align holes in diaphragm spring retainer (2) with threaded
bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.

Install six bolts (1) (metric) to secure diaphragm spring
retainer to clutch hub. Alternately tighten the bolts to 90-
110 in-lbs (10.2-12.4 Nm).

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

Install primary chaincase cover and gasket. See

10. Fill primary chaincase with lubricant. See

CHAIN, Changing Primary Chaincase Lubricant

sm02417

Narrow plate

Regular plate

Figure 5-31. Friction Plates

CLUTCH PACK AND BEARING

Complete Disassembly

Remove the primary chaincase cover. See

5.6 CLUTCH, Clutch Pack Only

CHAINCASE COVER, Removal

Remove clutch assembly. See

5.4 DRIVE COMPONENTS,

Removal

Follow all partial disassembly information under

NOTE

To avoid possible bearing damage, do not disassemble the
clutch shell and hub assembly unless the bearing, hub or shell
require replacement. Replace the bearing if disassembled.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 5-32

. With the transmission side up, remove

retaining ring from clutch hub groove.

Figure 5-33

. Supporting clutch shell in same orienta-

tion, use arbor press and a suitable press plug to press
hub from bearing in clutch shell.

See

Figure 5-34

. With the transmission side up, remove

retaining ring from groove in clutch shell bore.

5.6 CLUTCH, Clutch Pack Only

Figure 5-35

. Turn clutch shell over so that transmis-

sion side is down. Using arbor press and a suitable press
plug, press on inner race to remove bearing from clutch
shell bore.

Continue with Cleaning and Inspection found under

5-16 2009 Dyna Service: Drive

sm02419

Figure 5-32. Clutch Hub Retaining Ring

sm02421

Figure 5-33. Pressing Clutch Hub From Bearing

Assembly

Orient clutch shell in arbor press with transmission side
up. Be sure to support clutch shell bore on sprocket side
to avoid damage to ears on clutch basket. Using a suitable
press plug, press against outer race until bearing contacts
shoulder in clutch shell bore.

Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)

See

Figure 5-34

. Install retaining ring in groove of clutch

shell bore so that flat side of retaining ring is towards
bearing.

Turn clutch shell over so sprocket side is up. Center hub
in bearing. Be sure that bearing inner race is supported

with sleeve on transmission side. Press hub into bearing
until hub shoulder contacts bearing inner race.

See

Figure 5-32

. Turn assembly over so that the transmis-

sion side is up. Install retaining ring in groove of clutch
hub.

Place clutch assembly on bench oriented with the trans-
mission side down.

Soak all friction and steel plates in FORMULA+ TRANS-
MISSION AND PRIMARY CHAINCASE LUBRICANT (Part
No. 99851-05, qt.) for at least five minutes.

5.4 DRIVE COMPONENTS, Installation

Figure 5-36

. Install the narrow friction plate on the

clutch hub engaging tabs on plate with slots in clutch shell.

Install damper spring seat on clutch hub so that it seats
inboard of narrow friction plate.

Install damper spring on clutch hub with the concave side
up (facing opposite damper spring seat).

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

hub. Install seven remaining sets in the same manner,
alternating between steel plates and frictions plates.

11. Install pressure plate on clutch hub aligning holes in plate

with threaded bosses on hub.

12. See

Figure 5-37

. Seat diaphragm spring (1) in recess of

pressure plate with the concave side down.

13. Align holes in diaphragm spring retainer with threaded

bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.

14. Install six bolts (5) (metric) to secure diaphragm spring

retainer to clutch hub. Alternately tighten 90-110 in-lbs
(10.2-12.4 Nm).

15. Install clutch. See

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

16. Install primary chaincase cover and gasket. See

5.3 PRIMARY CHAINCASE COVER, Installation

17. Fill primary chaincase with lubricant. See

CHAIN, Changing Primary Chaincase Lubricant

2009 Dyna Service: Drive 5-17

sm02422

Figure 5-34. Install Clutch Shell Retaining Ring with Flat

Side Against Bearing

sm02424

Figure 5-35. Pressing Bearing From Clutch Shell

sm02426

Steel plate

Clutch hub

Damper spring seat

Damper spring

Starter ring gear

Primary chain sprocket

Narrow friction plate

Figure 5-36. Clutch Stackup

sm02427

Diaphragm spring

Jam nut

Adjuster screw

Retaining ring

Bolt (6) (metric)

Figure 5-37. Assembled Clutch

5-18 2009 Dyna Service: Drive

5.7

TRANSMISSION SPROCKET

REMOVAL

TOOL NAME

PART NUMBER

FINAL DRIVE SPROCKET LOCKING
TOOL

HD-46282-A

MAINSHAFT LOCKNUT WRENCH

HD-47910

PILOT

HD-94660-2

Remove primary chaincase. See

5.5 PRIMARY CHAIN-

CASE HOUSING, Removal

Remove debris deflector. See

2.21 DEBRIS DEFLECTOR

NOTE

Loosen both axle adjusters an equal number of turns to main-
tain wheel alignment.

Figure 5-38

. Remove rear axle retaining ring (3).

Loosen rear axle nut (2). Loosen both axle adjusters (1)
to release tension on the drive belt.

Only remove sprocket nut while transmission is installed
in frame. Failure to do so will result in damage to transmis-
sion and/or transmission stand.

Remove transmission sprocket.

Figure 5-39

. Remove two screws (1) and lock-

plate (2).

Figure 5-40

. Secure sprocket using FINAL DRIVE

SPROCKET LOCKING TOOL (Part No. HD-46282-
A)(3). Final drive sprocket locking tool must rest
against lower portion of rear fork pivot nut (2).

NOTE

Sprocket nut has a right-hand thread.

Install PILOT (Part No. HD-94660-2) on mainshaft.

Remove the sprocket nut using MAINSHAFT
LOCKNUT WRENCH (Part No. HD-47910) (1).

Remove belt from sprocket as sprocket is removed.

sm03754

Axle adjuster

Axle nut

Retaining ring

Figure 5-38. Axle Adjusters (Left Side Shown)

sm02428

Screw (2)

Lockplate

Sprocket nut

Sprocket

Main drive gear

Figure 5-39. Transmission Sprocket

sm02430

Mainshaft locknut wrench

Rear fork pivot nut

Final drive sprocket locking tool

3/4 inch breaker bar

Figure 5-40. Sprocket Nut Removal (Typical)

CLEANING AND INSPECTION

Using a non-volatile cleaning solvent, clean sprocket of
all grease and dirt.

Inspect belt and sprocket. See

1.13 REAR BELT AND

SPROCKETS, Inspection

Inspect both main drive gear and mainshaft seals. Replace
if damaged.

2009 Dyna Service: Drive 5-19

INSTALLATION

TOOL NAME

PART NUMBER

FINAL DRIVE SPROCKET LOCKING
TOOL

HD-46282-A

MAINSHAFT LOCKNUT WRENCH

HD-47910

PILOT

HD-94660-2

NOTE

Only install sprocket nut while transmission is installed in frame.
Failure to do so will result in damage to transmission and/or
transmission stand.

Place transmission sprocket in position. Install the belt on
the sprocket as the sprocket is installed on the main drive
gear.

NOTES

•

Exercise caution to avoid getting oil on the threads of the
sprocket nut or the integrity of the lock patch may be
compromised.

•

The transmission sprocket nut has right-hand threads.
Turn the nut clockwise to install on the main drive gear.

Figure 5-39

. Install the sprocket nut. The following

procedure is based on whether a new or used nut is being
used.

New sprocket nut: spread 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. Install the sprocket nut until finger tight.

Used sprocket nut: apply Loctite High Strength
Threadlocker 271 (red) to the threads of the sprocket
nut. Also spread 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.
Install the sprocket nut until finger tight.

Figure 5-41

. Lock transmission sprocket with the

FINAL DRIVE SPROCKET LOCKING TOOL (Part No. HD-
46282-A) (2). Final drive sprocket locking tool must rest
against upper portion of rear fork pivot nut (3).

Install PILOT (Part No. HD-94660-2) on mainshaft.

Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
47910) (1), tighten sprocket nut to 35 ft-lbs (47.5 Nm) initial
torque.

Loosen sprocket nut to remove initial torque.

Tighten sprocket nut to 35 ft-lbs (47.5 Nm).

Failure to use Main Drive Gear Remover and Installer can
cause premature failure of bearing and related parts.
(00540b)

Figure 5-42

. Scribe a line (3) on the transmission

sprocket nut (1). Continue the line on the transmission
sprocket (2) as shown.

Tighten the transmission sprocket nut an additional 35°
to 45°.

10. Install lockplate over transmission sprocket nut so that two

of lockplate's four drilled holes (diagonally opposite) align
with sprocket's two tapped holes. To find the best fit,
lockplate can be rotated to a number of positions and can
be placed with either side facing sprocket.

NOTE

Maximum allowable tightening of sprocket nut is 45° of clock-
wise rotation after a torque of 35 ft-lbs (47.5 Nm). Do not loosen
sprocket nut to align holes or nut will be under tightened.

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

tighten sprocket nut as necessary (up to the 45° maximum)
until sprocket and lockplate holes are in alignment.

12. See

Figure 5-39

. Install screws (1) through two of the four

holes in lockplate (2), then into two corresponding tapped
holes in sprocket (4).

NOTES

•

The screws have LOCTITE patches. With LOCTITE High
Strength Threadlocker 271 (red) reapplied before installa-
tion, the screws can be re-used up to three times.

•

BOTH screws MUST be used when installing the lockplate.

13. Tighten screws to 84-108 in-lbs (9.5-12.2 Nm).

14. Install primary chain assembly. See

5.4 DRIVE COMPON-

ENTS

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

15. Install primary chaincase cover. See

CHAINCASE COVER

16. Fill primary chaincase with lubricant. See

1.14 REAR BELT DEFLECTION

CHAIN

17. Verify pivot shaft torque. See

2.24 REAR FORK

18. Adjust belt tension. See

19. Verify vehicle alignment and tighten rear axle. See

2.12 VEHICLE ALIGNMENT

20. Install debris deflector. See

2.20 BELT GUARD

and

2.21 DEBRIS DEFLECTOR

CHAINCASE HOUSING, Removal

5-20 2009 Dyna Service: Drive

5.8

DRIVE BELT

REMOVAL

Remove rear wheel. See

2.5 REAR WHEEL, Removal

Remove primary chain, clutch, engine compensating
sprocket, and chain adjuster as an assembly. See

5.4 DRIVE COMPONENTS

Remove primary chaincase housing. See

5.5 PRIMARY

Remove lower shock absorber fasteners, allow rear fork
to rotate down. See

2.23 REAR SHOCK ABSORBERS

Slip drive belt from transmission sprocket and rear fork.

Inspect belt and sprockets. See

1.13 REAR BELT AND

SPROCKETS, General

INSTALLATION

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

Install belt over transmission sprocket and rear fork.

NOTE

See

Figure 5-43

. Handling of belt during installation can effect

belt durability.

Rotate rear fork up and install lower shock absorber
mounting fasteners. See

2.23 REAR SHOCK

ABSORBERS, Installation

Install the primary chaincase housing. See

5.5 PRIMARY

CHAINCASE HOUSING, Installation

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

Install primary chain assembly. See

5.4 DRIVE COMPON-

ENTS

Install primary chaincase cover. See

CHAINCASE COVER

Fill primary chaincase with lubricant. See

2.5 REAR WHEEL, Installation

CHAIN

Install rear wheel. See

Align vehicle. See

2.12 VEHICLE ALIGNMENT

Adjust belt tension. See

1.14 REAR BELT DEFLECTION,

Adjustment

5-22 2009 Dyna Service: Drive

6.1

FASTENER TORQUE VALUES

FASTENER TORQUE VALUES IN THIS
CHAPTER

The table below lists torque values for all fasteners presented
in this chapter.

NOTES

TORQUE VALUE

FASTENER

6.5 CLUTCH RELEASE COVER, Assembly and
Installation

10.2-13.6 Nm

90-120 in-lbs

Clutch cable fitting

6.5 CLUTCH RELEASE COVER, Assembly and
Installation

9.5-12.2 Nm

84-108 in-lbs

Clutch release cover screws

6.6 TRANSMISSION ASSEMBLY, Assembly

74.6-88.2 Nm

55-65 ft-lbs

Mainshaft/countershaft nuts

6.8 TRANSMISSION CASE, Installation

13.6-20.3 Nm

120-180 in-lbs

Neutral switch

6.6 TRANSMISSION ASSEMBLY, Installation

9.5-14.9 Nm

84-132 in-lbs

Oil spout fastener

6.6 TRANSMISSION ASSEMBLY, Assembly

13.6-17.0 Nm

120-150 in-lbs

Shift drum detent arm fastener

6.6 TRANSMISSION ASSEMBLY, Assembly

6.4-7.1 Nm

57-63 in-lbs

Shift drum lock plate fasteners

6.4 SHIFTER LINKAGE, Adjustment

10.8-16.3 Nm

96-144 in-lbs

Shifter linkage locknut

6.8 TRANSMISSION CASE, Assembly

24.4-29.8 Nm

18-22 ft-lbs

Shifter rod lever screw

6.4 SHIFTER LINKAGE, Adjustment

9.0-13.6 Nm

80-120 in-lbs

Shift rod jam nut

6.6 TRANSMISSION ASSEMBLY, Installation

17.6-24.4 Nm

13-18 ft-lbs

Transmission case, 5/16 in. hardware

6.6 TRANSMISSION ASSEMBLY, Installation

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

6.8 TRANSMISSION CASE, Installation

19.0-28.5 Nm

14-21 ft-lbs

Transmission drain plug

6.8 TRANSMISSION CASE, Installation

46.1-52.9 Nm

34-39 ft-lbs

Transmission mounting bolts, final torque

6.8 TRANSMISSION CASE, Installation

20.3 Nm

15 ft-lbs

Transmission mounting bolts, initial
torque

6.6 TRANSMISSION ASSEMBLY, Installation

9.5-14.9 Nm

84-132 in-lbs

Transmission top cover

6.8 TRANSMISSION CASE, Installation

9.5-14.9 Nm

84-132 in-lbs

VSS fastener

2009 Dyna Service: Transmission 6-1

6.2

SPECIFICATIONS: TRANSMISSION

SPECIFICATIONS

Table 6-1. Transmission Specifications

DATA

TRANSMISSION

6-speed forward constant

mesh

Type

Part No. 99851-05 (qt)

FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE
LUBRICANT

32 oz.

Capacity

946.4 ml

Table 6-2. Gear Specifications

OVERALL GEAR RATIO

GEAR

3.34

First (low)

2.31

Second

1.72

Third

1.39

Fourth

1.18

Fifth

1.00

Sixth (high)

NOTE

Final gear ratios indicate the number of mainshaft revolutions
required to drive the output sprocket one revolution.

SERVICE WEAR LIMITS

Table 6-3. Main Drive Gear Specifications

IN.

MAIN DRIVE GEAR (6th)

0.0076-0.043

0.0003-0.0017

Bearing fit in transmission
case (loose)

0.025-0.076

0.001-0.003

Fit in bearing (press-fit)

none

End play

Table 6-4. Mainshaft Tolerance Specifications

IN.

MAINSHAFT TOLERANCE

0.00-0.08

0.000-0.003

Mainshaft runout

none

Mainshaft end play

0.05-0.66

0.002-0.026

5th gear end play (axial)

0.009-0.052

0.0004-0.0020

5th gear clearance (radial)

0.023-0.056

0.0009-0.0022

Main drive gear (6th) fit

Table 6-5. Countershaft Tolerance Specifications

IN.

COUNTERSHAFT
TOLERANCE

0.00-0.08

0.000-0.003

Countershaft runout

0.025-0.08

0.001-0.003

Countershaft end play

0.03-0.58

0.001-0.023

1st gear end play (axial)

0.010-0.052

0.0004-0.0020

1st gear clearance (radial)

0.03-1.02

0.001-0.40

2nd gear end play (axial)

0.010-0.052

0.0004-0.0020

2nd gear clearance
(radial)

0.03-1.07

0.001-0.042

3rd gear end play (axial)

0.010-0.052

0.0004-0.0020

3rd gear clearance
(radial)

0.03-0.71

0.001-0.028

4th gear end play (axial)

0.010-0.052

0.0004-0.0020

4th gear clearance
(radial)

Table 6-6. Shifter Dog Wear Limit Specifications

IN.

SHIFTER DOG

0.381-2.845

0.015-0.112

1st

0.533-3.454

0.021-0.136

2nd

0.356-2.997

0.014-0.118

3rd

0.838-2.921

0.033-0.115

4th

0.406-2.921

0.016-0.115

5th

0.660-3.124

0.026-0.123

6th

Table 6-7. Side Door Bearing Specifications

IN.

SIDE DOOR BEARING

0.0025-0.0356

0.0001-0.0014

Fit in side door (tight)

-0.018

-0.0007

Fit on countershaft (tight)

+0.025

+0.001

Fit on countershaft (loose)

-0.018

-0.0007

Fit on mainshaft (tight)

+0.025

+0.001

Fit on mainshaft (loose)

Table 6-8. Shifter Fork Specifications

IN.

SHIFTER FORKS

0.102-0.305

0.004-0.012

Shifter fork to cam groove end
play

0.102-0.4060

0.004-0.016

Shifter fork to dog ring end
play

6.55

0.258

First and second gear shift
fork pad thickness wear limit

5.03

0.198

Third and fourth gear shift fork
pad thickness wear limit

6.55

0.258

Fifth and sixth gear shift fork
pad thickness wear limit

6-2 2009 Dyna Service: Transmission

6.3

TRANSMISSION

POWER FLOW

Figure 6-1

. The 6-speed transmission consists of two

parallel shafts supporting six gears each. The longer, or
mainshaft (7), also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft (8).

Each gear on the mainshaft is in constant mesh with a corres-
ponding gear on the countershaft. Each of these six pairs of
gears makes up a different speed in the transmission.

The transmission gears are divided into two types, gears that
rotate with the shaft, and freewheeling gears that ride on
bearings and spin freely on the shaft. A gear that rotates with
the shaft always meshes with a freewheeling gear. Also, three
dog rings are able to slide sideways on the shaft. These dog
rings are used to change transmission speeds. The dogs, or
projections, on the sides of the dog rings, engage dogs on
adjacent freewheeling gears, transmitting power through the
transmission.

Gear shifting is accomplished by three forks which fit into
grooves machined into the dog rings that slide on the guide
hubs. The position of the shifter forks is controlled by a drum-
shaped shifter cam located in the transmission side door.

Neutral

Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft 1st, 2nd, 3rd
and 4th gears are rotating, but no power is transferred to the
countershaft since countershaft 1st, 2nd, 3rd and 4th gears
are freewheeling gears.

1st Gear

When the transmission is shifted into first gear, the dog ring
between countershaft 1st and 2nd, which rotates with the
countershaft, engages countershaft 1st, which has been spin-
ning freely on the countershaft driven by mainshaft 1st.

Now countershaft 1st is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft

6th to turn. Countershaft 6th transmits the power to the main
drive gear and the sprocket as shown (1).

2nd Gear

Second gear is engaged when the dog ring between counter-
shaft 1st and 2nd is shifted out of countershaft 1st and engages
countershaft 2nd. This locks countershaft 2nd to the counter-
shaft to complete the power flow as shown (2).

3rd Gear

Two shifter forks are used to make the shift from second to
third. One fork moves the dog ring between countershaft 1st
and 2nd to its neutral position, while another fork engages the
dog ring between countershaft 3rd and 4th with countershaft
3rd. This locks countershaft 3rd to the countershaft to complete
the power flow as shown (3).

4th Gear

Fourth gear is engaged when the dog ring between counter-
shaft 3rd and 4th is shifted out of countershaft 3rd and engages
countershaft 4th. This locks countershaft 4th to the countershaft
to complete the power flow as shown (4).

5th Gear

Two shifter forks are used to make the shift from fourth to fifth.
One fork moves the dog ring between countershaft 3rd and
4th to its neutral position, while another fork engages the dog
ring between mainshaft 5th and 6th with mainshaft 5th. This
locks mainshaft 5th to the mainshaft to complete the power
flow as shown (5).

6th Gear

The shift from fifth to sixth gear occurs when the dog ring
between mainshaft 5th and 6th is shifted out of mainshaft 5th,
and is shifted directly into the main drive gear (6th gear). The
main drive gear is locked to the mainshaft resulting in a direct
one-to-one drive ratio from the clutch to the sprocket as shown
(6).

2009 Dyna Service: Transmission 6-3

6.4

SHIFTER LINKAGE

ADJUSTMENT

NOTE

Not all models are equipped with adjustable linkage.

The shift rod is set at the factory and should not need adjust-
ment under normal circumstances. However, if full engagement
or full lever travel is not achieved, adjust the shift rod.

See

Figure 6-2

. Remove locknut (3), lockwasher and flat

washer to free front end of shift rod from inner shift arm.

Loosen jam nuts (1) and adjust rod (2) as necessary.

Install flat washer, lockwasher and locknut (3) to fasten
front end of shift rod to inner shift arm.

Tighten locknut (3) to 96-144 in-lbs (10.8-16.3 Nm)

Tighten jam nuts to 80-120 in-lbs (9.0-13.6 Nm).

sm03004

Jam nut (2)

Rod

Locknut

Figure 6-2. Shifter Rod