Harley Davidson 2011 Touring Models. Service Manual - page 39

5.4 DRIVE COMPONENTS, Removal

CHAINCASE COVER, Removal

Remove starter. See

7.10 STARTER, Removal

Remove primary chain, clutch, and compensating sprocket.
See

See

Figure 5-19

. Remove five sealing fasteners (5) and

remove primary chaincase housing (11). Discard the
crankcase gasket (10) and sealing fasteners.

sm05037

1. Seal
2. Lock ring
3. Bearing
4. Dowel pin
5. Sealing fastener (5)
6. Chain tensioner fasteners
7. Chain tensioner
8. Drain plug and O-ring
9. Shifter shaft bushings
10. Crankcase gasket
11. Primary chaincase housing

Figure 5-19. Primary Chaincase Housing

INSPECTION

Inspect primary chaincase for cracks or damaged gasket
surface.

Check the mainshaft bearing. Replace if bearing does not
rotate freely. Replace the lip seal. See

5.5 PRIMARY

CHAINCASE HOUSING, Mainshaft Bearing and Lip Seal

Inspect shifter shaft bushings. Replace if worn or dam-
aged. See

5.5 PRIMARY CHAINCASE HOUSING, Shifter

Shaft Bushings

MAINSHAFT BEARING AND LIP SEAL

Removal

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)

Remove lip seal from bearing bore on transmission side
of primary chaincase. Use a seal remover or rolling head
pry bar for best results.

Remove retaining ring from groove on transmission side
of bearing.

Support inner primary chaincase on transmission side of
bearing.

NOTE

Support inner primary chain case area on transmission side
while pressing bearing out of primary chaincase. The force
needed to remove bearing may cause damage to primary chain
case.

Place primary chaincase in arbor press. Press out bearing
from clutch side applying pressure to the outer race.

Installation

Inspect the bearing bore to verify that it is clean and
smooth. Install retaining ring in groove on pulley side of
primary chaincase.

Place primary chaincase in arbor press with the transmis-
sion side up.

Support the bearing support area on the clutch side of the
primary chaincase.

NOTE

Support the bearing support area on clutch side while pressing
bearing into bore. The force needed to press bearing into
position may force and unsupported primary chain case to
become damaged.

Apply a thin film of oil to outer diameter of bearing.

Applying pressure to the outer race, press

new

bearing

letter side up, into bore until it makes solid contact with
the bearing support area.

See

Figure 5-20

. Retaining ring (1) must be oriented as

shown to prevent blocking of oil passage (2). Install
retaining ring to lock position of bearing in bore. Verify that
the ring is fully seated in the groove and is in proper orient-
ation.

5-10 2011 Touring Service: Drive

NOTES

•

The lip garter spring side of the oil seal is also identified
by the words "OIL SIDE".

•

Install oil seal with a seal driver that will press only against
outer rim of oil seal, NOT against the inner area.

•

The minimum allowable depth of the seal is reached when
the outer edge of the seal carrier is flush with the machined
surface of the primary housing. The maximum allowable
depth of the seal is reached when the seal carrier contacts
the mainshaft bearing snap ring.

Install mainshaft oil seal:

Lubricate the O.D. of the

new

seal with Screamin'

Eagle Assembly Lube (part No. 94971-09.)

See

Figure 5-21

. With the lip garter spring side

(stamped "oil side") facing toward the bearing, press
squarely on the outer edge of oil seal until outer edge
of seal is flush with machined surface of inner primary
housing.

Lubricate the bearing and seal lip with multi-purpose
grease or Screamin' Eagle Assembly Lube (part No.
94971-09.)

sm02385

1. Retaining ring
2. Oil passage

Figure 5-20. Retaining Ring Orientation

sm02387

Figure 5-21. Oil Seal

MAINSHAFT BEARING INNER RACE

TOOL NAME

PART NUMBER

MAINSHAFT BEARING INNER RACE
REMOVER/INSTALLER

HD-34902-C

Removal

NOTE

The bearing inner race must be positioned on the shaft a pre-
cise distance to properly align with the bearing outer race in
the primary chaincase. To remove and install the bearing inner
race, use the combination MAINSHAFT BEARING INNER
RACE REMOVER/INSTALLER (Part No. HD-34902-C).

See

Figure 5-22

. Install end cap (2) into end of mainshaft.

Position puller (3) around mainshaft, under bearing inner
race.

Turn forcing screw (4) clockwise while holding puller to
remove bearing.

sm05961

1. Bearing inner race
2. End cap
3. Puller
4. Forcing screw

Figure 5-22. Pulling Mainshaft Inner Bearing Race

2.21 REAR FORK, Installa-

2011 Touring Service: Drive 5-11

Installation

See

Figure 5-23

. Slide bearing inner race (1) onto main-

shaft.

NOTE

Extension shaft has left-hand threads.

Thread extension shaft (2) onto end of mainshaft.

Position installer sleeve (4) over extension shaft and
against bearing inner race. Apply graphite lubricant to
threads of extension shaft.

Place two washers (5) over threaded portion of extension
shaft and install nut.

Tighten nut (6) while holding extension shaft stationary
with wrench on flats (3) at end of screw threads. Press
race onto shaft until edge of race contacts step on shaft.

Lubricate race with Screamin' Eagle Assembly Lube (Part
No. 94971-09.)

sm03455

1. Bearing inner race
2. Extension shaft
3. Wrench flat
4. Installer sleeve
5. Washers
6. Nut

Figure 5-23. Installing Bearing Race

SHIFTER SHAFT BUSHINGS

See

Figure 5-24

. Press out old bushings (1) using an arbor

press. Inspect the bushing bore to verify that it is clean
and smooth.

Press

new

bushings into each side of the bore using an

arbor press. Installed bushing must be flush to 0.010 in.
(0.25 mm) below edge of bore.

sm05050

1. Shifter shaft bushing (2)
2. Primary chaincase

Figure 5-24. Shifter Shaft Bushings

INSTALLATION

NOTE

Cover mainshaft clutch hub splines with tape to prevent the
splines damaging the inner primary cover oil seal.

Verify pivot shaft torque. See

tion

NOTE

See

Figure 5-25

. In next step, be sure dowels (1) in crankcase

gasket (2) engage holes in crankcase.

See

Figure 5-26

. Place crankcase gasket in place on

gasket surface (2). Be sure dowels in gasket engage dowel
holes (3).

Spread a thin film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket. Be careful not to damage
mainshaft seal when installing chaincase over the primary
bearing inner race on the mainshaft.

See

Figure 5-27

. Insert

new

sealing fasteners.

See

Figure 5-28

. Tighten fasteners in sequence shown to

25-27 ft-lbs (33.9-36.6 Nm).

Install the primary chain, clutch, and compensating
sprocket as an assembly. See

5.4 DRIVE COMPONENTS,

Installation

Install chain tensioner assembly.

Install starter. See

7.10 STARTER, 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.

5-12 2011 Touring Service: Drive

Install primary chaincase cover. See

CHAINCASE COVER, Installation

10. Fill primary chaincase with lubricant. See

CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant

11. Adjust rear belt tension.

12. Connect negative battery cable.

sm02381

1. Dowel
2. Crankcase gasket

Figure 5-25. Crankcase Gasket

sm02382

1. Crankcase
2. Gasket surface
3. Dowel holes

Figure 5-26. Crankcase

sm02383

Figure 5-27. Sealing Fastener

sm05039

Figure 5-28. Sealing Fastener Torque Sequence

5.4 DRIVE COMPONENTS, Removal

2011 Touring Service: Drive 5-13

5.6

CLUTCH

REMOVAL AND INSTALLATION

To remove the clutch without disassembly or for installation
instructions, see

CLUTCH PACK ONLY

Partial Disassembly

This procedure can be performed on the motorcycle without
removing the clutch shell or hub.

Remove primary chaincase cover. See

CHAINCASE COVER, Removal

See

Figure 5-29

. 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).

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 primary chaincase lubricant 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.

NOTE

Springs are identified by a dab of paint on one face. Refer to
the parts catalog to verify the correct spring is installed.

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 2011 Touring Service: Drive

sm02704b

Damper spring seat

Bolt (6) (metric)

10.

Diaphragm spring retainer

Mainshaft nut (metric)

11.

Clutch hub

Diaphragm spring

12.

Pressure plate

Clutch shell

13.

Bearing

Friction plate (9)

14.

Steel plate (8)

Retaining ring

15.

Retaining ring

Narrow friction plate

8. Damper spring

Figure 5-29. Clutch Shell Assembly

Assembly

NOTE

Submerge and soak all friction plates in primary chaincase
lubricant for at least five minutes.

See

Figure 5-30

. Install the narrow friction plate on the

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

See

Figure 5-29

. Install damper spring seat (9) on clutch

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

5.3 PRIMARY CHAINCASE COVER, Installation

2011 Touring Service: Drive 5-15

NOTE

See

Figure 5-35

. Notice damper spring (4) orientation with

respect to damper spring seat (3).

See

Figure 5-29

. 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 70-
100

in-lbs

(7.9-11.3 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

CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant

sm02417

1. Narrow plate
2. Regular plate

Figure 5-30. 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

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 5-31

. With the transmission side up, remove

retaining ring from clutch hub groove.

See

Figure 5-32

. 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 5-33

. With the transmission side up, remove

retaining ring from groove in clutch shell bore.

See

Figure 5-34

. 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

5.6 CLUTCH, Clutch Pack Only

sm02419

Figure 5-31. Clutch Hub Retaining Ring

5.4 DRIVE COMPONENTS, Installation

5-16 2011 Touring Service: Drive

sm02421

Figure 5-32. 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 5-33

. 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 5-31

. 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 primary chaincase
lubricant for at least five minutes.

See

Figure 5-35

. 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 then 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 5-36

. 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 70-100

in-lbs

(7.9-11.3 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

CHAINCASE LUBRICANT, Changing Primary Chaincase
Lubricant

sm02422

Figure 5-33. Install Clutch Shell Retaining Ring with Flat

Side Against Bearing

2011 Touring Service: Drive 5-17

5.7

TRANSMISSION SPROCKET

REMOVAL

TOOL NAME

PART NUMBER

FINAL DRIVE SPROCKET LOCKING
TOOL

HD-46282A

MAINSHAFT LOCKNUT WRENCH

HD-47910

PILOT

HD-94660-2

Remove primary chaincase. See

5.5 PRIMARY CHAIN-

CASE HOUSING

Loosen drive belt tension. See

SPROCKETS

NOTE

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

See

. Remove two screws (1) and lockplate

(2).

See

Figure 5-38

. Install FINAL DRIVE SPROCKET

LOCKING TOOL (Part No. HD-46282A) (2) so that arm
of tool rests against bottom of rear fork pivot (1).

NOTE

Sprocket nut has a right-hand thread.

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

Remove the sprocket nut (3) using MAINSHAFT
LOCKNUT WRENCH (Part No. HD-47910) (1).

Remove sprocket, allowing belt to slip from sprocket as
sprocket is removed.

sm02428

1. Screw (2)
2. Lockplate
3. Sprocket nut
4. Sprocket
5. Main drive gear

Figure 5-37. Transmission Sprocket

sm05983

1. Rear fork pivot
2. Final drive sprocket locking tool
3. Sprocket nut

Figure 5-38. Sprocket Nut Removal

CLEANING AND INSPECTION

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

Inspect belt and sprocket. See

SPROCKETS, Inspection

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

INSTALLATION

TOOL NAME

PART NUMBER

FINAL DRIVE SPROCKET LOCKING
TOOL

HD-46282A

MAINSHAFT LOCKNUT WRENCH

HD-47910

PILOT

HD-94660-2

NOTE

Install sprocket nut only 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.

If reusing the sprocket nut, apply Loctite High Strength
Threadlocker 271 (red) to the threads of the sprocket nut.

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.

See

. Carefully spread a small quantity of clean

engine oil on the inside face of the sprocket nut (3) and
the outside face of the sprocket (4) where the surfaces of

2011 Touring Service: Drive 5-19

the two parts contact each other. Install the sprocket nut
until finger tight.

See

Figure 5-39

. Lock transmission sprocket with the

FINAL DRIVE SPROCKET LOCKING TOOL (Part No. HD-
46282A) (2). Arm of locking tool must rest against upper
portion of rear fork pivot (1).

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

Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
47910), tighten sprocket nut to 100 ft-lbs (135.7 Nm) initial
torque.

See

. Relocate locking tool as when removing

sprocket nut.

Loosen sprocket nut one full turn.

Relocate locking tool as shown in

Figure 5-39

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

11. See

Figure 5-40

. Scribe lines (3) on the transmission

sprocket nut (1). Continue the lines onto the transmission
sprocket (2) as shown.

12. Tighten sprocket nut an additional 35-40 degrees.

13. Install lockplate over transmission sprocket nut so that two

of lockplate's four drilled holes 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 degrees
of clockwise 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.

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

continue to tighten sprocket nut (up to the 45 degrees
maximum) until sprocket and lockplate holes are in align-
ment.

NOTES

•

New screws have LOCTITE patches.

•

Screws can be re-used up to three times if LOCTITE High
Strength Threadlocker 271 (red) is applied before installa-
tion.

•

To be sure of the lockplate's security, BOTH screws must
be installed in the lockplate.

15. See

5.3 PRIMARY CHAINCASE COVER

. Install two screws (1) to secure lockplate

(2) to sprocket (4).

16. Tighten screws to 90-120

in-lbs

(10.2-13.6 Nm).

17. 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.

18. Install primary chaincase cover and

new

gasket. See

19. Fill primary chaincase with lubricant. See

CHAINCASE LUBRICANT

20. Verify pivot shaft torque. See

2.21 REAR FORK

21. Adjust belt tension. See

SPROCKETS

sm05984

1. Rear fork pivot
2. Final drive sprocket locking tool
3. Sprocket nut

Figure 5-39. Sprocket Nut Installation

35°

45°

sm05068a

1. Transmission sprocket nut
2. Transmission sprocket
3. Scribed lines

Figure 5-40. Transmission Sprocket Nut Final Tightening

1.12 DRIVE BELT AND SPROCKETS, Setting Belt

5-20 2011 Touring Service: Drive

5.8

DRIVE BELT

REMOVAL AND ADJUSTMENT

Adjustment

See

Deflection

Removal

Remove rear wheel and rear fork. See

2.21 REAR FORK

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

CHAINCASE HOUSING, Removal

Remove belt from transmission sprocket.

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.

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 and primary chaincase
cover. Fill primary chaincase with lubricant. See

5.4 DRIVE

COMPONENTS

Install rear fork and rear wheel. See

2.21 REAR FORK

Adjust belt tension. See

SPROCKETS

2011 Touring Service: Drive 5-21

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

10.2-13.6 Nm

90-120

in-lbs

Clutch release cover screws

6.6 TRANSMISSION ASSEMBLY, Assembly

115.3-128.8 Nm

85-95 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, 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

6.8 TRANSMISSION CASE, Assembly

24.4-29.8 Nm

18-22 ft-lbs

Shifter rod lever screw

6.4 SHIFTER LINKAGE, Shifter Rod

9.0-13.6 Nm

80-120

in-lbs

Shifter rod locknut

6.6 TRANSMISSION ASSEMBLY, Installation

17.6-24.4 Nm

13-18 ft-lbs

Side door fasteners

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

10.2-13.6 Nm

90-120

in-lbs

Transmission top cover

6.8 TRANSMISSION CASE, Installation

9.5-14.9 Nm

84-132

in-lbs

VSS fastener

2011 Touring 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

Part No. 99824-03/00QT (qt)

SYN3 20W50 Oil

32 oz.

Capacity

946.4 ml

Table 6-2. Transmission Gear Ratios

GEAR RATIO

GEAR

3.34

First (low)

2.31

Second

1.72

Third

1.39

Fourth

1.19

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 Clearance Specifications

IN.

SHIFTER DOG

0.33-3.07

0.013-0.121

1st

0.41-3.51

0.016-0.138

2nd

0.25-3.17

0.010-0.125

3rd

0.46-3.28

0.018-0.129

4th

0.18-2.97

0.007-0.117

5th

0.56-3.33

0.022-0.131

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)

-0.010

-0.0004

Fit on countershaft (tight)

+0.030

+0.0012

Fit on countershaft (loose)

-0.010

-0.0004

Fit on mainshaft (tight)

+0.030

+0.0012

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