Content .. 36 37 38 39 ..

Harley Davidson 2011 Touring Models. Service Manual - page 38

4.20

ACTIVE EXHAUST (HDI)

EXHAUST VALVE ACTUATOR

Removal

See

Figure 4-43

. Remove two fasteners (4) and washers (3)

to release active exhaust valve actuator (2) from bottom of
battery tray (1).

Installation

Install two fasteners to secure active exhaust valve actuator
to bottom of battery tray. Tighten screws to 32-40

in-lbs

(3.6-

4.5 Nm).

sm05957

1. Battery tray
2. Actuator
3. Washer
4. Fastener

Figure 4-43. Active Exhaust Actuator

EXHAUST VALVE ACTUATOR CABLE

Removal

Remove exhaust valve actuator. See

4.20 ACTIVE

EXHAUST (HDI), Exhaust Valve Actuator

Remove cable as follows:

Push on metal sleeve at end of cable housing to
release plastic insert from slot in cable guide.

Release cable from groove at center of actuator wheel
and gently pull barrel end from hole.

See

Figure 4-44

. Release cable housing (2) from cable

clip (1).

Installation

Install cable as follows:

Gently push barrel end into hole in actuator wheel
until cable engages groove at center.

Push on metal sleeve at end of cable housing to
engage plastic insert in slot of cable guide.

Install exhaust valve actuator. See

4.20 ACTIVE

EXHAUST (HDI), Exhaust Valve Actuator

See

Figure 4-44

. Secure cable housing (2) with cable clip

(1).

sm05958

1. Cable clip
2. Cable housing

Figure 4-44. Cable Routing

ACTIVE EXHAUST VALVE

General

The active exhaust valve is not repairable. Replace the rear
exhaust header pipe if the valve is damaged or fails. See

4.19 EXHAUST SYSTEM

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2011 Touring Service: Fuel System 4-35

4.21

INTAKE LEAK TEST

GENERAL

Do not allow open flame or sparks near propane. Propane
is extremely flammable, which could cause death or ser-
ious injury. (00521b)

Read and follow warnings and directions on propane
bottle. Failure to follow warnings and directions can result
in death or serious injury. (00471b)

NOTES

•

To prevent false readings, keep air cleaner cover installed
when performing test.

•

Do not direct propane into air cleaner; false readings will
result.

•

Be careful when testing vehicle with Screamin' Eagle air
cleaner assembly. This type of air cleaner has an open
backing plate. Even with air cleaner cover on, directing
nozzle too close to backing plate can give false readings.

LEAK TESTER

TOOL NAME

PART NUMBER

PROPANE ENRICHMENT KIT

HD-41417

Parts List

•

Standard 14 oz. propane cylinder.

•

PROPANE ENRICHMENT KIT (Part No. HD-41417).

Tester Assembly

See

Figure 4-45

. Make sure valve knob (6) is closed (fully

clockwise).

Screw valve assembly (5) onto propane bottle (1).

Tester Adjustment

See

Figure 4-45

. Press and hold trigger button (8).

Slowly open valve knob (6) until pellet in flow gauge (7)
rises 5-10 SCFH on gauge.

Release trigger button.

sm02629

1. Propane bottle
2. Nozzle
3. Copper tube
4. Hose
5. Valve assembly
6. Valve knob
7. Flow gauge
8. Trigger button
9. Hanger

Figure 4-45. Leak Tester

PROCEDURE

Start engine.

Warm up engine to operating temperature.

NOTE

Do not direct propane stream toward air cleaner. If propane
enters air cleaner, a false reading will be obtained.

See

Figure 4-46

. Aim nozzle (3) toward possible sources

of leak such as intake manifold mating surfaces.

Press and release trigger button (2) to dispense propane.
Tone of engine will change when propane enters source
of leak. Repeat as necessary to detect leak.

HOME

4-36 2011 Touring Service: Fuel System

When test is finished, close valve knob (turn knob fully
clockwise).

sm02630

1. Propane bottle
2. Trigger button
3. Nozzle

Figure 4-46. Checking for Leaks

HOME

2011 Touring Service: Fuel System 4-37

4.22

EVAPORATIVE EMISSIONS CONTROL SYSTEM

GENERAL

Motorcycles sold in some markets are equipped with an
evaporative (EVAP) emissions control system. See

Figure 4-47

The EVAP system functions as follows:

•

The fuel vapor vent tube connected to the vapor valve on
the fuel tank top plate allows fuel vapors in the fuel tank
to be vented to the charcoal canister. If the motorcycle is
tipped, the vapor valve also prevents the loss of gasoline
through the vent tube.

•

Under certain engine conditions, the ECM (working in
conjunction with the EFI system relay) opens the purge
solenoid. Negative pressure (vacuum) draws the fuel
vapors stored in the charcoal canister through the purge

tube to the induction module, where they are burned as
part of the normal combustion process.

Keep evaporative emissions vent lines away from exhaust
and engine. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00266a)

NOTE

The EVAP system has been designed to operate with a min-
imum of maintenance. Check that all tubes are correctly routed
and properly connected. Also, verify that the tubes are not
pinched or kinked, and that there is no contact with the engine
parts.

sm05935

Fuel vapor vent tube

Top caddy

Purge solenoid

Fuel tank top plate

Fastener (2)

Canister-to-induction module tube

Canister-to solenoid tube

Charcoal canister

5. Cable clip

Figure 4-47. Evaporative Emissions Control System (EVAP)

VAPOR VALVE

NOTE

See

Figure 4-48

. The vapor valve is not serviceable. Damage

or failure of the vapor valve requires replacement of the fuel
tank top plate. See

4.6 FUEL TANK TOP PLATE

HOME

4-38 2011 Touring Service: Fuel System

sm04094

Figure 4-48. Fuel Tank Top Plate With Vapor Valve

FUEL VAPOR VENT TUBE

Removal

Remove seat. See

2.25 SEAT

Remove fuel tank console:

Remove screws to release front and rear of console
from fuel tank.

Lay a clean shop towel on forward part of rear fender.

FLHR/C:

Remove console and lay upside down on

shop towel.

FLHX, FLHTC/U, FLHTK, FLTRX, FLTRU:

Remove

filler cap. Remove console and lay upside down on
shop towel. Install filler cap.

See

Figure 4-47

. Remove fuel vapor vent tube (6) from

vapor valve fitting on fuel tank top plate (7).

Disconnect vent tube from fitting on canister (9).

Remove vapor vent tube from motorcycle.

Installation

See

Figure 4-47

. Connect fuel vapor vent tube (6) onto

vapor valve fitting of fuel tank top plate (7).

Connect vent tube to fitting on charcoal canister (9) marked
"TANK".

Install fuel tank console:

FLHR/C:

Position console on fuel tank.

FLHX, FLHTC/U, FLHTK, FLTRX, FLTRU:

Remove

filler cap and position console on fuel tank. Install filler
cap.

Verify harnesses and vent tube are not pinched.

Install screws to fasten front and rear of console to
fuel tank.

Tighten screws to 36-60

in-lbs

(4.1-6.8 Nm).

Install seat. See

2.25 SEAT

CANISTER-TO-SOLENOID TUBE

Removal

Remove seat. See

2.25 SEAT

See

Figure 4-49

. Remove purge tube (2) from fitting of

purge solenoid and canister.

Installation

Install end of purge tube with curved hose onto lower fitting
of canister.

Install opposite end onto purge solenoid.

Install seat. See

2.25 SEAT

SOLENOID-TO-INDUCTION MODULE TUBE

Removal

Remove seat. See

2.25 SEAT

Remove fuel tank. See

4.5 FUEL TANK

See

Figure 4-49

. Remove purge tube (3) from purge

solenoid.

Remove cable clip on purge tube from frame backbone.

Disconnect tube from fitting on induction module.

Remove purge tube from motorcycle.

Installation

Route purge tube rearward under frame crossmember
and into area near purge solenoid, then along bottom of
frame backbone toward induction module. Connect to fit-
ting on induction module.

See

Figure 4-49

. Route purge tube under frame cross-

member and install on upper fitting (3) of purge solenoid.

Secure purge tube to bottom of frame backbone with

new

retainer.

Install fuel tank. See

4.5 FUEL TANK

Install seat. See

2.25 SEAT

sm05932

1. Fuel vapor vent tube
2. Canister-to-solenoid purge tube
3. Solenoid-to-induction module purge tube

Figure 4-49. Purge Tube Connections

HOME

2011 Touring Service: Fuel System 4-39

PURGE SOLENOID

Removal

Remove seat. See

2.25 SEAT

Remove top electrical caddy and remove purge solenoid
from caddy. Lay caddy aside. See

7.8 ELECTRICAL

CADDIES

See

Figure 4-50

. Remove purge solenoid connector (1).

Remove purge tubes (2, 3) from purge solenoid.

Remove purge solenoid from motorcycle.

sm05933

1. Purge solenoid connector
2. Canister-to-solenoid purge tube
3. Solenoid-to-induction module purge tube

Figure 4-50. Purge Solenoid

Installation

See

Figure 4-50

. Install purge tube to induction module

(3) onto fitting of purge solenoid closest to the connector
cavity.

Install purge tube from charcoal canister (2) onto purge
solenoid.

Install purge solenoid connector (1).

Secure solenoid to top caddy and install top caddy. See

7.8 ELECTRICAL CADDIES

Check all routing to be sure that tubes are not pinched or
kinked, and that there is no contact with hot exhaust or
engine parts.

Install seat. See

2.25 SEAT

CHARCOAL CANISTER

Removal

Remove seat. See

2.25 SEAT

Remove saddlebags. See

2.26 SADDLEBAGS

Remove side covers.

Remove battery. See

1.23 BATTERY MAINTENANCE

Remove two fasteners to free top caddy hold-down
bracket.

See

Figure 4-51

. Remove cable strap (1) securing main

harness to frame near left side caddy.

Remove screws (2) securing left side caddy to frame.

See

Figure 4-52

. Disconnect fuel vapor vent tube (1) from

canister fitting marked "TANK."

Disconnect purge tube (2) from canister fitting marked
"PURGE."

10. See

Figure 4-53

. Remove three ground ring terminals from

left ground stud (1).

11. Remove two ground ring terminals from right ground stud

(2).

12. Remove two screws to release charcoal canister from

frame cross member.

13. Work canister down into battery tray, right end first, and

remove from motorcycle.

Installation

Slide the charcoal canister under electrical harnesses, fit-
ting end first, and work into place.

Secure canister with two screws and tighten to 10-15

in-

lbs

(1.1-1.7 Nm).

See

Figure 4-53

. Install three ground ring terminals on

left-side ground stud (1).

Install two ground ring terminals on right-side ground stud
(2). Battery chassis ground terminal should be placed on
stud first.

See

Figure 4-52

. Connect purge tube (2) (charcoal canister

to purge solenoid) to lower canister fitting marked
"PURGE."

Connect fuel vapor vent tube (1) (vapor valve to charcoal
canister) to upper canister fitting marked "TANK."

See

Figure 4-51

. Install left side caddy and tighten two

fasteners (2) to 72-96

in-lbs

(8.1-10.9 Nm).

Secure main harness to frame with cable strap (1).

sm05929

1. Cable strap
2. Fasteners

Figure 4-51. Left Electrical Caddy

HOME

4-40 2011 Touring Service: Fuel System

sm05930

1. Fuel vapor vent tube
2. Purge tube

Figure 4-52. Purge Tube Connections

sm05931

1. Left ground stud
2. Right ground stud

Figure 4-53. Chassis Ground Studs

Check all routing to be sure that tubes are not pinched or
kinked, and that there is no contact with hot exhaust or
engine parts.

10. Install top caddy hold-down bracket. Tighten two fasteners

to 32-40

in-lbs

(3.6-4.5 Nm) .

11. Install battery. See

1.23 BATTERY MAINTENANCE

12. Install side covers.

13. Install saddlebags. See

2.26 SADDLEBAGS

14. Install seat. See

2.25 SEAT

HOME

2011 Touring Service: Fuel System 4-41

TABLE OF CONTENTS

SUBJECT

............................................................................................................................

PAGE NO.

DRIVE

5.1

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

5.4 DRIVE COMPONENTS, Installation

20.3-25.8 Nm

15-19 ft-lbs

Chain tensioner fasteners

5.6 CLUTCH, Clutch Pack Only

7.9-11.3 Nm

70-100

in-lbs

Clutch diaphragm spring retainer bolts

5.4 DRIVE COMPONENTS, Installation

94.9-108.5 Nm

70-80 ft-lbs

Clutch hub mainshaft nut

5.4 DRIVE COMPONENTS, Installation

135.7 Nm

100 ft-lbs

Compensating sprocket bolt: Initial
torque

5.4 DRIVE COMPONENTS, Installation

190.0 Nm

140 ft-lbs

Compensating sprocket bolt: Initial
torque

5.6 CLUTCH, Clutch Pack and Bearing

7.9-11.3 Nm

70-100

in-lbs

Diaphragm spring retainer bolts

5.3 PRIMARY CHAINCASE COVER, Installa-
tion/See sequence in the procedure

12.2-13.6 Nm

108-120

in-lbs

Primary cover fasteners

5.5 PRIMARY CHAINCASE HOUSING, Installation

33.9-36.6 Nm

25-27 ft-lbs

Sealing fasteners

5.3 PRIMARY CHAINCASE COVER, Installation

24-30 Nm

18-22 ft-lbs

Shift lever fasteners

5.3 PRIMARY CHAINCASE COVER, Installation

10.2-12.4 Nm

90-110

in-lbs

Shift lever shaft fastener

5.7 TRANSMISSION SPROCKET, Installation/LOC-
TITE patch, use 3-5 times

10.2-13.6 Nm

90-120

in-lbs

Transmission lockplate screws

5.7 TRANSMISSION SPROCKET, Installation/Plus
an additional 35-45 degrees final torque

47.5 Nm

35 ft-lbs

Transmission sprocket nut, final

5.7 TRANSMISSION SPROCKET, Installation/Right
hand threads, initial torque only, apply several
drops of LOCTITE THREADLOCKER 271 (red) to
last few threads.

135.7 Nm

100 ft-lbs

Transmission sprocket nut, initial

5.7 TRANSMISSION SPROCKET, Installation

47.5 Nm

35 ft-lbs

Transmission sprocket nut (maximum)

HOME

2011 Touring Service: Drive 5-1

5.2

SPECIFICATIONS: DRIVE

SPECIFICATIONS

Table 5-1. Sprocket Teeth

NUMBER OF

TEETH

ITEM

DRIVE

Engine

Primary

Clutch

Transmission

Final

Rear wheel

Table 5-2. Clutch Specifications

DESCRIPTION

CLUTCH

Wet-multiple disc

Type

1/16-1/8 in. (1.6-3.2 mm)

Clutch lever freeplay
(after internal adjustment)

Table 5-3. Overall Drive Ratios

RATIO

GEAR

9.593

1st Gear

6.650

2nd Gear

4.938

3rd Gear

4.000

4th Gear

3.407

5th Gear

2.875

6th Gear

NOTE

Overall gear ratios indicate number of engine revolutions
required to drive rear wheel one revolution.

HOME

5-2 2011 Touring Service: Drive

5.3

PRIMARY CHAINCASE COVER

GENERAL

The primary chaincase is a sealed housing containing the
primary chain, chain tensioner, clutch, engine compensating
sprocket and alternator.

For information on primary chain lubrication, see

1.9 PRIMARY

CHAINCASE LUBRICANT

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect negative battery cable.

Drain the primary chaincase lubricant. See

1.9 PRIMARY

CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant

Remove left passenger footboard from rear fork bracket.

Remove fastener to release front footboard forward bracket
from frame weldment. Remove two fasteners to free jiffy
stand and front footboard rear bracket from frame weld-
ment as an assembly.

Remove heel and toe shift lever fasteners from shift lever
shaft and pull shift levers from shift lever shaft. Remove
rubber spacer. An alternate method is to remove socket
head fastener to release inner shift arm then pull shift lever
shaft and heel toe shift lever assembly from primary
chaincase bore.

See

Figure 5-1

. Remove nine short (1) and four long (2)

cover fasteners and cover.

sm003716

1. Short cover fasteners
2. Long cover fasteners

Figure 5-1. Primary Chaincase Cover: Touring Models

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.

See

Figure 5-2

. Install

new

cover gasket (1).

See

Figure 5-1

. Apply a drop of Loctite Threadlocker 243

(blue) (Part no. 99642-97). Install nine short (1) and four
long (2) primary cover fasteners in positions shown. Snug
fasteners.

See

Figure 5-3

. Tighten primary cover fasteners to 108-

120

in-lbs

(12.2-13.6 Nm) in the sequence shown.

sm03717

1. Cover gasket
2. Primary chaincase cover
3. Mass dampener/screw (Japan only)

Figure 5-2. Primary Chaincase Cover Gasket

HOME

2011 Touring Service: Drive 5-3

sm003718

Figure 5-3. Primary Chaincase Cover Torque Sequence:

Touring Models

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incomplete
disengagement, clutch drag and/or difficulty in finding
neutral at engine idle. (00199b)

Place motorcycle in an upright position and fill primary
chaincase. See

1.9 PRIMARY CHAINCASE LUBRICANT,

Changing Primary Chaincase Lubricant

If installing heel-toe shift levers onto shift lever shaft:

Install inboard shift lever (toe) onto splines of shift
lever shaft. When properly installed, fastener hole is
countersunk at the top.

Install outboard shift lever (heel) onto splines of shift
lever shaft. When properly installed, fastener hole is
countersunk at the bottom.

Install fasteners to fasten heel-toe shift levers to shift
lever shaft. Tighten shift lever fasteners to 18-22 ft-
lbs (24-30 Nm).

If just installing inner shift arm onto shift lever shaft:

Install rubber spacer onto shift lever shaft. Install shift
lever shaft into primary chaincase bore.

Install inner shift arm onto splines of shift lever shaft.

Install fastener to attach inner shift arm to shift lever
shaft. Tighten fastener to 90-110

in-lbs

(10.2-12.4

Nm).

Install jiffy stand and rider footboard. See

2.49 FOOT-

BOARDS AND FOOTRESTS

Install passenger left footboard. See

2.49 FOOTBOARDS

AND FOOTRESTS

Connect negative battery cable.

HOME

5-4 2011 Touring Service: Drive

5.4

DRIVE COMPONENTS

REMOVAL

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-48219

Disconnect the battery, negative cable first.

Remove primary chaincase cover. See

5.3 PRIMARY

CHAINCASE COVER, Removal

See

Figure 5-4

. Secure chain tensioner with a cable tie

as shown. Make sure the tail of the cable tie hangs down
past the primary housing when secured. This will serve
as a reminder to remove the cable tie before installing the
primary cover during assembly.

See

Figure 5-5

. Remove chain tensioner fasteners (2) and

remove chain tensioner (1).

NOTE

Marking one of the outboard links of the primary chain to help
identify the original direction of rotation during assembly may
prolong service life.

Use a colored marker to mark one of the links of the
primary chain to help identify the original direction of
rotation during assembly.

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 5-6

. Loosen locknut (3).

Remove retaining ring (1) and release plate (2).

Do not apply heat to remove the clutch hub nut. Fuel vapor
and possible fuel mixture in crankcase oil is extremely
flammable and highly explosive, which could result in
death or serious injury. (00440b)

NOTES

•

Use only PRIMARY DRIVE LOCKING TOOL (Part No. HD-
48219) to remove and install components. Do not use
PRIMARY DRIVE LOCKING TOOL (Part No. HD-41214)
to remove or install components. Damage to components
can occur if this tool is used.

•

The mainshaft nut has left-hand threads. Turn clockwise
to remove.

See

Figure 5-7

. Install PRIMARY DRIVE LOCKING

TOOL (Part No. HD-48219) (2) between the teeth of the
engine and clutch sprockets as shown. Rotate clutch hub
mainshaft nut (4) clockwise to remove.

See

Figure 5-8

. Install PRIMARY DRIVE LOCKING

TOOL (Part No. HD-48219) (2) between the teeth of the
engine and clutch sprockets as shown. Rotate compens-
ating sprocket bolt (1) counterclockwise to remove.

10. See

Figure 5-9

. Remove bolt (9), sprocket retainer (8) and

thrust washer (7).

11. Remove clutch assembly, primary chain and compensating

sprocket assembly as a single assembly.

sm05036

Figure 5-4. Securing Chain Tensioner

sm06987

1. Chain tensioner
2. Chain tensioner fasteners

Figure 5-5. Chain Tensioner

HOME

2011 Touring Service: Drive 5-5

sm02393

1. Retaining ring
2. Release plate
3. Locknut

Figure 5-6. Clutch

sm06958

1. Engine sprocket
2. Primary drive locking tool
3. Clutch sprocket
4. Clutch hub nut

Figure 5-7. Removing Clutch Hub Mainshaft Nut

sm06959

1. Bolt
2. Primary drive locking tool

Figure 5-8. Removing Compensating Sprocket Bolt

sm04526

1. Shaft extension
2. Large spring washer (2)
3. Medium spring washer (2)
4. Small spring washer
5. Sliding cam
6. Compensating sprocket
7. Thrust washer
8. Sprocket retainer
9. Bolt

Figure 5-9. Compensating Sprocket

HOME

5-6 2011 Touring Service: Drive

INSTALLATION

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-48219

See

Figure 5-9

. Install compensating sprocket assembly.

Install shaft extension (1) with bearing journal facing
away from vehicle. Apply a thin layer of primary
chaincase oil to the splines and bearing journal.

See

Figure 5-10

. Install large spring washers (1).

Outer diameter of spring washers should be con-
tacting each other.

Install medium spring washers (2). Outer diameter of
spring washers should be contacting each other.

See

Figure 5-9

. Install small spring washer (4) so that

outer diameter will contact sliding cam (5), once
installed.

Install sliding cam with flat face contacting small spring
(4). Lubricate sliding cam ramps with primary chain-
case oil.

Place drive components [primary chain, compensating
sprocket (6) (with text "this side out" facing away from
motorcycle), and clutch assembly] into position. The
clutch hub and shaft extension are splined, so a slight
rotation of the chain drive will aid installation.

NOTE

When installing sprocket retainer (8) make sure that thrust
washer (7) does not fall off sprocket retainer or that it does
not get pinched between the sprocket retainer and exten-
sion shaft. A small amount of white lithium grease will help
hold the thrust washer to the sprocket retainer.

Install thrust washer (7) and sprocket retainer (8).

NOTES

•

When installing bolt (9), make sure the spring washers
are properly aligned and that spring nearest rotor assembly
has not slipped between extension and rotor hub.

•

Make sure the thrust washer has not slipped between the
sprocket and sprocket retainer.

See

Figure 5-11

. Install PRIMARY DRIVE LOCKING

TOOL (Part No. HD-48219) as shown. Install

new

bolt (1) by hand and snug against sprocket retainer.
Tighten compensating sprocket to 100 ft-lbs (135.7
Nm).

Loosen compensating sprocket back one full turn (360
degrees).

Re-tighten compensating sprocket to 140 ft-lbs (190.0
Nm).

Rotate compensating sprocket to make sure there is
a light pressure on sprocket from the springs, no
clearance should be felt. A slight rotation should be
possible by hand with transmission in neutral.

NOTE

Clutch hub mainshaft nut has left handed threads, so turn
counterclockwise to install.

Clean and prime threads of nut. Apply two drops of
LOCTITE THREADLOCKER 262 (red) to the threads
of the clutch hub mainshaft nut. Start nut onto main-
shaft and tighten hand tight.

See

Figure 5-12

. Install PRIMARY DRIVE LOCKING

TOOL (Part No. HD-48219) as shown. Tighten clutch hub
mainshaft nut to 70-80 ft-lbs (94.9-108.5 Nm). Remove
primary drive locking tool.

See

Figure 5-13

. Install release plate (5) with locknut (2)

and adjuster screw (3) into clutch hub bore. The word
"OUT" stamped on the release plate should face outward.

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)

Inspect retaining ring (4) and replace if necessary. Install
retaining ring in clutch hub bore to lock release plate in
position. Verify that the retaining ring is completely seated
in the groove.

Adjust clutch. See

1.11 CLUTCH, Adjustment

NOTE

Primary chain tensioner is non-repairable. If tensioner is worn
or damaged, assembly must be replaced.

See

Figure 5-14

. If primary chain tensioner becomes dis-

assembled, assemble in order shown.

See

Figure 5-15

. Locate end of spring rod (2) on roll pin

(3).

See

Figure 5-16

. Slide wedge (2) of primary chain ten-

sioner in direction of arrow until all travel is removed. Hold
shoe (1) and wedge (2) together.

See

Figure 5-17

. Insert cable tie (2) as shown to hold

wedge in place. Make sure end of cable tie is located
below primary chain tensioner to serve as a reminder to
remove cable tie before installing primary cover.

NOTE

Primary chain tensioner will not complete chain adjustment
until vehicle is ridden. Vehicle must be test ridden after ten-
sioner removal/installation to verify proper adjustment.

10. See

Figure 5-18

. Install primary chain tensioner (1) and

tighten fasteners (2) to 15-19 ft-lbs (20.3-25.8 Nm).
Remove cable tie.

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed to
prevent primary chaincase leaks.

11. Install primary chaincase cover and fill with lubricant. See

5.3 PRIMARY CHAINCASE COVER, Installation

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2011 Touring Service: Drive 5-7