Harley Davidson 2005 touring models. Service repair manual

HOME

SHIFTER CAM ASSEMBLY/SHIFTER FORKS

7.4

DISASSEMBLY

CAUTION

Pulling shifter cam assembly from dowels allows left

1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

support block to rotate freely, which can cause screws

MAXI-FUSE, REMOVAL.

and washers to drop into transmission case if left

2. Remove the exhaust system in two sections. See Sec-

loosely installed.

tion 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-

See Figure 7-3. Remove the four hex head screws (with

flat washers) to free the right and left shifter cam support

blocks. Raise shifter pawl and lift shifter cam assembly

3. Remove the magnetic drain plug at the bottom right side

from dowels on deck of transmission case.

of the oil pan and drain the transmission lubricant into a

suitable container. Remove the fill plug/dipstick.

See CLEANING AND INSPECTION, steps 2 and 3, on

the next page. If necessary, disassemble shifter cam

4. Using fingers and flat tip screwdriver, remove two elbow

assembly as follows:

connectors from neutral switch studs. Using 7/8 inch box

end wrench, remove neutral switch and O-ring from

1WARNING

transmission top cover. Remove preformed vent hose

from the top cover fitting, if necessary.

Always wear proper eye protection when removing re-

taining rings. Use the correct retaining ring pliers. Verify

5. Remove the five socket head screws from the transmis-

that the tips of the pliers are not damaged or excessively

sion top cover. Remove the top cover from the transmis-

worn. Slippage may propel the ring with enough force to

sion case. Remove and discard the cover gasket.

cause eye injury.

f1889b7x

Hex Head

Screw

Retaining

Flat

Ring

Washer

Shifter Cam

Spiral

Lock Ring

Roller

Bearing

Hex Head

Screw

Left

Support Block

Spring

Flat

Detent

Washer

Arm

Roller

Bearing

Pivot

Screw

Retaining

Ring

Spring

Sleeve

Right

Support Block

Figure 7-3. Shifter Cam Assembly

7-6

2005 Touring: Transmission

HOME

12. Remove the fork shaft from the hole on the right side of

the transmission case. See Figure 7-5. Remove the

Inner

Retaining

shifter forks from the mainshaft and countershaft gear

Ramp

Ring

grooves.

13. To replace the transmission gears or side door bearings,

Cable

see Section

7.6 MAINSHAFT/COUNTERSHAFT. To

Fitting

replace the main drive gear, see Section

7.7 MAIN

DRIVE GEAR/BEARING.

CLEANING AND INSPECTION

1WARNING

Clutch Cable

Compressed air can pierce the skin and cause injury.

Coupling

Never use your hand to check for leaks or to determine

f1896x7x

air flow rates. Wear safety glasses to shield your eyes

from flying dirt and debris. Failure to comply could result

Figure 7-4. Clutch Release Cover Assembly

in death or serious injury.

1. Clean all parts with solvent (except left and right support

a. Retract detent arm and slide right support block off

blocks if roller bearings installed). Blow dry with low

end of shifter cam. Remove pivot screw to release

pressure compressed air.

detent arm, spring sleeve and spring. Remove and

2. Inspect roller bearings. Verify that bearings rotate freely

discard retaining ring. Press against inner race of

without sticking.

roller bearing to remove from support block. Discard

roller bearing.

3. Inspect the shifter cam for cracks or wear. Inspect the

ends for grooves or pitting. Install new roller bearings

b. Moving to opposite side, remove spiral lock ring

whenever the shifter cam is replaced.

from groove at left end of shifter cam. Using a small

knife, push on end of spiral lock ring working tip of

4. Check the shifter fork shaft. Replace if bent or damaged.

blade under edge of ring. Raise end of ring until free

5. Using a small carpenter’s square, verify that the shifter

of ring groove. Work around circumference of ring to

fork shafts are square. If a fork does not rest directly on

alternately pull spirals from ring groove. Discard

the square, then it is bent and must be replaced. See

ring.

Figure 7-6.

c. Slide left support block off end of shifter cam.

Remove and discard retaining ring. Press against

inner race of roller bearing to remove from support

f1892x7x

block. Discard roller bearing.

Slide rubber boot off clutch cable adjuster. Holding cable

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

inch wrench. Back jam nut away from cable adjuster.

Move adjuster toward jam nut to introduce a large

amount of free play at hand lever.

Remove six socket head screws to free clutch release

cover from transmission side door. Remove and discard

gasket.

10.

Remove retaining ring and lift inner ramp out of clutch

release cover. Turn the inner ramp over so that ball sock-

ets are facing outboard. Remove hook of ramp from but-

Fork

ton on coupling. Remove coupling from clutch cable end.

Shaft

See Figure 7-4.

11.

Unscrew the cable fitting from the clutch release cover.

Figure 7-5. Remove Fork Shaft/Shifter Forks

Remove clutch cable and fitting.

(Right Side View)

2005 Touring: Transmission

7-7

HOME

ASSEMBLY

f1888x7x

See upper frame of Figure 7-8. Find the shifter fork with

the centered pin. Holding the fork so that the pin is posi-

Carpenter’s

tioned at the rear of the transmission case, install the

Square

fork in the countershaft gear fork groove. See Figure 7-9.

Slide the two outer forks into the mainshaft gear fork

grooves so that the pins are positioned on the inside (off-

Shifter

set outboard). After installation, the pins of all three forks

Fork

should be in alignment.

SHIFTER FORKS

7976

Mainshaft

Centered

Shifter

Shaft

Fork Shaft

Figure 7-6. Check Shifter Forks for Squareness

Offset

Outboard

Countershaft

Right

Side

Left

Side

SHIFTER CAM ASSEMBLY

7975

Right

0.165 in. (4.19 mm)

Support Block

Left

Minimum

Support Block

(2 places on each fork)

Shifter

Cam

4th gear shifter fork

1st and 2nd gear shifter fork

3rd and 5th gear shifter fork

f1100bxx

Figure 7-7. Shifter Fork Identification

Inspect the shifter forks for wear. With a micrometer or

dial caliper, measure the width of the forks where they

contact the gear fork grooves. Replace any fork that

measures less than 0.165 inch (4.19 mm). See Figure 7-

Detent

Shifter

Arm

Pawl

Inspect the neutral switch. Depress plunger and observe

the action. Plunger should spring back without binding.

Figure 7-8. Install Shifter Forks/Shifter Cam

Switch is non-repairable and must be replaced if defec-

tive. See ASSEMBLY, step 11.

7-8

2005 Touring: Transmission

HOME

c. Place right support block under ram of arbor press.

8256

Center new roller bearing over bore with the let-

Countershaft

tered side up. Using a suitable driver, press against

outer race until bearing makes firm contact with the

Mainshaft

counterbore. Install new retaining ring with the flat

side in against the bearing (beveled side out). See

lower frame of Figure 7-10.

Fork Groove

d. Hold spring so that ends are pointing to the right.

Insert long end of spring sleeve into right side of

spring. Insert pivot screw into left side of spring

sleeve. With roller facing screw head, slide detent

arm onto short end of spring sleeve positioning arm

between spring ends. Start pivot screw into

Fork Groove

threaded hole in right support block positioning sup-

port block between spring ends. Tighten pivot screw

to 84-108 in-lbs (9.5-12.2 Nm). Retract detent arm

and slide right support block onto end of shifter

cam. See Figure 7-11.

Figure 7-9. Shifter Fork Groove Locations

7410

Roller

3. Insert the fork shaft into the hole on the right side of the

Bearing

transmission case. Slide the shaft through the shifter

forks and into the drilling on the left side of the case. See

Figure 7-5.

4. Check the sliding movement of the forks and gears. All

parts should move freely without binding.

Retaining Ring

Beveled Side Out

Spiral

Lock Ring

1WARNING

Left

Always wear proper eye protection when installing re-

Support Block

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

Left Side

cause eye injury.

7411

If disassembled, assemble shifter cam assembly as fol-

lows:

Roller

Bearing

Retaining Ring

a. Place left support block under ram of arbor press.

Beveled Side Out

Center new roller bearing over bore with the let-

tered side up. Using a suitable driver, press against

outer race until bearing makes firm contact with the

counterbore. Install new retaining ring with the flat

side in against the bearing (beveled side out). See

upper frame of Figure 7-10.

Right

b. Place left support block onto end of shifter cam.

Support Block

Start bottom end of new spiral lock ring into ring

groove. Alternately work around circumference of

Right Side

ring feeding each spiral into the ring groove a sec-

tion at a time. When complete, verify that spiral lock

ring is fully seated in the groove.

Figure 7-10. Shifter Cam Assembly

2005 Touring: Transmission

7-9

HOME

b. Lubricate O-ring with clean transmission lubricant.

7411

c. Using

7/8 inch box end wrench, install neutral

switch with O-ring in the transmission top cover.

Tighten to 120-180 in-lbs (13.6-20.3 Nm).

d. Install the two elbow connectors on neutral switch

studs.

Pivot

NOTE

Screw

The neutral switch is not polarity sensitive, so the elbow con-

nectors can be attached to either stud.

12. See Figure 7-4. Install clutch cable fitting into clutch

Detent

release cover. Do not tighten at this time.

Arm

Spring

NOTE

Spring Sleeve

Replace cable fitting O-ring if damaged or deformed.

Figure 7-11. Shifter Cam Assembly

13. Hold clutch cable coupling with button facing outboard.

Place cable end in recess of coupling. With ball sockets

To ensure proper location, verify that four locating dow-

facing outboard, place hook of inner ramp on button of

els are in place on the deck of the transmission case.

coupling. Holding inner ramp and coupling together, turn

the assembly over. Place inner ramp (ball socket side

Raise the shifter cam pawl and place the shifter cam

down) over balls in outer ramp sockets. Install the retain-

assembly over the locating dowels. See Figure 7-12.

ing ring so that the opening is above and to the right of

While aligning the holes in the support blocks with the

the outer ramp tang slot in the clutch release cover.

dowels on the deck of the transmission case, slide the

shifter forks as necessary so that the fork pins engage

14. Verify that the two locating dowels are in place on the

the channels in the shifter cam. See lower frame of Fig-

transmission side door. Hang a new gasket on the dow-

ure 7-8.

els.

Hand start the hex head screws (with flat washers) to

15. Holding clutch release cover in position against trans-

fasten the right and left support blocks to the transmis-

mission side door, install six socket head screws. Alter-

sion case. Alternately tighten the four support block

nately tighten screws to 84-132 in-lbs (9.5-14.9 Nm) in

screws to 84-108 in-lbs (9-12 Nm) in a crosswise pat-

the sequence shown in Figure 7-13.

tern.

16. Tighten clutch cable fitting to 36-60 in-lbs (4-7 Nm).

NOTE

Check the gear engagement and clearance in every gear to

make sure assembly and alignment is correct.

f1891x7x

Obtain a new top cover gasket and align the holes with

those in the transmission case. Align the holes in the top

cover with those in the gasket. Install the five socket

head screws and tighten to 84-132 in-lbs (9.5-14.9 Nm).

The long screw is installed in the center hole on the left

side of the top cover.

Locating

10. Install preformed vent hose to top cover fitting, if re-

Dowels

moved.

NOTE

Whenever the transmission top cover is removed, be sure to

install neutral switch after top cover installation to ensure

proper switch engagement.

11. Install the neutral switch in the transmission top cover as

follows:

a. Roll the motorcycle back and forth to verify that the

transmission is in NEUTRAL.

Figure 7-12. Place Support Blocks on Locating Dowels

7-10

2005 Touring: Transmission

HOME

19.

Fill the transmission with 20-24 oz. (590-710 ml) of trans-

f1893x7x

mission lubricant or until the lubricant level on the dipstick

of the filler plug is at the F(ULL) mark with the motorcycle

in a level, upright position and the filler plug resting on the

threads.

Use only Harley-Davidson SEMI-SYNTHETIC TRANS-

MISSION LUBRICANT: Part No.’s 99892-84 (quart),

98853-96 (case of quarts), 99891-84 (gallon), or 98852-

96 (case of gallons).

20.

Install the transmission filler plug/dipstick in the clutch

release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5

Nm).

21.

Adjust the clutch cable. See Section

6.3 CLUTCH,

ADJUSTMENT.

22.

Install the exhaust system. See Section 3.8 INSTALL-

Figure 7-13. Clutch Release Cover Torque Sequence

ING ENGINE IN CHASSIS, steps 46-52.

23.

Install maxi-fuse. See Section

8.3 SYSTEM FUSES,

17. Check the O-ring on the transmission lubricant drain plug

MAXI-FUSE, INSTALLATION.

for tears, cuts or general deterioration. Replace as nec-

essary.

CAUTION

Do not overtighten filler or drain plugs. Overtightening

plugs may cause leaks.

18. Install the transmission lubricant drain plug and tighten

to 14-21 ft-lbs (19-28 Nm).

2005 Touring: Transmission

7-11

HOME

CLUTCH RELEASE COVER

7.5

REMOVAL/DISASSEMBLY

Clutch

7960

Release

1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,

Cover

MAXI-FUSE, REMOVAL.

2. Remove the exhaust system in two sections. See Sec-

tion 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-

3. Remove the magnetic drain plug at the bottom right side

of the oil pan and drain the transmission lubricant into a

suitable container. Remove the filler plug/dipstick.

4. Remove six socket head screws to free clutch release

cover from transmission side door. Depress clutch lever

to break the cover seal, and then remove and discard

gasket.

Tang

5. Slide rubber boot off clutch cable adjuster. Holding cable

Ramp

Inner

Slot

adjuster with 1/2 inch wrench, loosen jam nut using 9/16

Connector

Ramp

inch wrench. Back jam nut away from cable adjuster.

Button

Move adjuster toward jam nut to introduce a large

amount of free play at hand lever.

Ball

Socket

1WARNING

Always wear proper eye protection when removing re-

Coupling

taining rings. Use the correct retaining ring pliers. Verify

Outer

that the tips of the pliers are not damaged or excessively

Ramp

worn. Slippage may propel the ring with enough force to

cause eye injury.

Cable

Balls

End

6. Remove retaining ring securing ball and ramp mecha-

Recess

Tang

nism to clutch release cover.

7. See Figure 7-14. Lift inner ramp out of clutch release

cover. Turn the inner ramp over so that ball sockets are

facing outboard. Remove hook of ramp from button on

Figure 7-14. Clutch Release Cover Assembly

coupling. Remove coupling from clutch cable end.

8. Remove balls from outer ramp sockets. Remove outer

ramp from clutch release cover.

See Figure 7-14. Check the recess in the clutch release

cover casting where the inner and outer ramps are

9. Unscrew the cable fitting from the clutch release cover.

retained. There should be no wear/lips worn into the

Remove clutch cable and fitting.

bore that would catch the ramps and cock them, causing

improper clutch adjustment.

Check clutch cable for damage and frayed or worn ends.

CLEANING AND INSPECTION

Check cable fitting O-ring for cuts, tears or signs of dete-

rioration.

Wash the ball and ramp components in cleaning solvent.

Inspect the three balls and the ball socket surfaces on

ASSEMBLY/INSTALLATION

both the inner and outer ramps for wear, pitting, surface

breakdown and other damage.

Install clutch cable fitting into clutch release cover. Do

Check fit of the inner ramp hub in the outer ramp.

not tighten cable fitting at this time.

Replace both parts if excessive wear is noted.

Inspect the inner/outer ramp retaining ring for damage or

NOTE

distortion.

Replace cable fitting O-ring if damaged or deformed.

7-12

2005 Touring: Transmission

HOME

Holding clutch release cover in position, install six socket

head screws. Tighten screws to 84-132 in-lbs (9.5-14.9

7957

Outer

Nm) in the sequence shown in Figure 7-13.

Ramp

Tighten clutch cable fitting to 36-60 in-lbs (4-7 Nm).

Ball

Ball in

Socket

10. Check the O-ring on the transmission lubricant drain plug

Socket

for tears, cuts or general deterioration. Replace as nec-

essary. Install the transmission lubricant drain plug and

tighten to 14-21 ft-lbs (19-28 Nm).

CAUTION

Do not overtighten filler or drain plugs. Overtightening

plugs may cause leaks.

Clutch

Tang

Release

11. Remove the filler plug from the clutch release cover, if

Cover

installed. See Figure 7-16. Check the O-ring for tears,

Balls

cuts or general deterioration. Replace as necessary.

Coupling

See Figure 7-17.

Inner

Ramp

12. Fill the transmission with

20-24 oz. (590-710 ml) of

transmission lubricant or until the lubricant level on the

dipstick of the filler plug is at the F(ULL) mark with the

motorcycle in a level, upright position and the filler plug

Figure 7-15. Install Outer Ramp and Balls

resting on the threads.

Use only Harley-Davidson SEMI-SYNTHETIC TRANS-

2. See Figure 7-15. Place outer ramp in clutch release

MISSION LUBRICANT: Part No.’s 99892-84 (quart),

cover recess with tang in cover slot.

98853-96 (case of quarts), 99891-84 (gallon), or 98852-

96 (case of gallons).

3. Apply a multi-purpose grease to the balls and outer

ramp sockets. Place a ball in each of three outer ramp

13. Install the transmission filler plug/dipstick in the clutch

sockets.

release cover. Tighten the plug to 25-75 in-lbs (2.8-8.5

4. Hold coupling with button facing outboard. Place cable

Nm).

end in recess of coupling. With ball sockets facing out-

14. Adjust the clutch cable. See Section

6.3 CLUTCH,

board, place hook of inner ramp on button of couplng.

ADJUSTMENT.

Holding inner ramp and coupling together, turn the

assembly over.

5. Place inner ramp (ball socket side down) over balls in

outer ramp sockets.

8496

Clutch

Release

Cover

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.

6. Install the retaining ring so that the opening is above and

Filler

to the right of the outer ramp tang slot in the clutch

Plug

release cover.

7. Verify that the two locating dowels are in place on the

transmission side door. Hang a new gasket on the dow-

els.

Figure 7-16. Transmission Case (Right Side)

2005 Touring: Transmission

7-13

HOME

MAINSHAFT/COUNTERSHAFT

7.6

NOTE

Fork

Check the eight digit number stamped on the transmission

Shaft

case just above the side door. If the third digit is “9,” then the

Countershaft

transmission was built for Japan only. If the digit is “0,” then it

Locknut

was built for all countries except Japan. If servicing a Japa-

nese transmission, follow the steps under REMOVAL below

and then see Appendix D.1 JAPANESE MAINSHAFT/COUN-

TERSHAFT for disassembly and assembly instructions.

REMOVAL

Remove the exhaust system in two sections. See Sec-

tion 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-

Mainshaft

Remove the shifter cam and shifter fork assemblies. See

Locknut

7969

Section

7.4 SHIFTER CAM ASSEMBLY/SHIFTER

FORKS, DISASSEMBLY.

Remove the primary chaincase cover. Remove clutch

Figure 7-18. Remove Mainshaft/Countershaft Locknuts

assembly, primary chain, and compensating sprocket

components. Remove the starter jackshaft assembly

and primary chaincase. See Section

6.5 PRIMARY

7970

CHAINCASE, REMOVAL.

Remove oil filler spout and starter. See Section

5.4

STARTER, REMOVAL, steps 6-12.

Remove the bearing inner race from the transmission

mainshaft. See Section

6.5 PRIMARY CHAINCASE,

MAINSHAFT BEARING INNER RACE, REMOVAL.

Remove the oil slinger assembly (with two-piece push

rod and clutch release bearing components).

Lock the transmission. This can be accomplished by

manually engaging the shifter dogs of any two gears

(mainshaft or countershaft) with the shifter dogs of an

adjacent gear and then turning the mainshaft counter-

clockwise.

Remove the locknut from both the mainshaft and coun-

tershaft. Use an air impact wrench for best results. See

Figure 7-18. Remove the spacer from each shaft.

Side

Rear

Door

Remove the six socket head screws (bottom four with

Indent

flat washers) to free both the side door and transmission

exhaust bracket from the transmission case. Pull the

Figure 7-19. Remove Transmission Side Door

side door, mainshaft and countershaft from the transmis-

sion case as a single assembly. Remove and discard the

DISASSEMBLY

door gasket. See Figure 7-19.

NOTE

DO NOT USE A HAMMER TO REMOVE THE SIDE DOOR.

1WARNING

If the side door sticks or binds on the locating dowels, gently

Always wear proper eye protection when removing re-

pry open using the indents at each side of the door. See Fig-

ure 7-19.

taining rings. Use the correct retaining ring pliers. Verify

that the tips of the pliers are not damaged or excessively

10. To remove the main drive gear, refer to Section 7.7 MAIN

worn. Slippage may propel the ring with enough force to

DRIVE GEAR/BEARING, REMOVAL.

cause eye injury.

2005 Touring: Transmission

7-15

HOME

3559

CAUTION

Supporting the gears is necessary to provide support for

the side door bearing inner races. Failure to support the

gears will result in bearing damage.

13. Support the countershaft 1st gear and press out the

countershaft.

14. Remove the mainshaft 1st gear.

15. Support the mainshaft 4th gear and press out the main-

shaft.

16. Remove the spacer from the mainshaft. Remove the

Figure 7-20. Note Gear Location During Disassembly

mainshaft 4th gear, thrust washer and retaining ring.

Remove the split cage bearing from the mainshaft race.

NOTE

17. Remove the spacer from the countershaft. Remove the

Use the TRANSMISSION SHAFT RETAINING RING PLI-

countershaft 4th gear and the countershaft 1st gear.

ERS, Part No. J-5586, to remove all mainshaft and counter-

Remove the thrust washer and retaining ring. Gently pull

shaft retaining rings. Note each gear and its location as it is

apart the split cage bearing and remove.

removed. See Figure 7-20.

1. Position the assembly on a bench with the side door

CLEANING AND INSPECTION

down, mainshaft on the left hand side.

Clean all parts in cleaning solvent and blow dry with

2. See A in Figure 7-21. Working from the end of the coun-

compressed air.

tershaft toward the side door, remove the retaining ring

from the countershaft.

Check gear teeth for damage. Replace the gears if they

are pitted, scored, rounded, cracked or chipped.

3. Remove the countershaft 5th gear.

Inspect the engaging dogs on the gears. Replace the

4. Remove the countershaft 2nd gear and thrust washer.

gears if the dogs are rounded, battered or chipped.

Inspect the side door bearings. Bearings must rotate

5. See B in Figure 7-21. Gently pull apart the split cage

freely without drag. Replace the bearings if pitted or

bearing and remove.

grooved. Proceed as follows:

6. Remove the retaining ring and the countershaft 3rd gear.

a. Remove the retaining rings and press the bearings

out of the side door.

7. See C in Figure 7-21. Moving to the mainshaft, remove

the mainshaft 2nd gear.

CAUTION

8. See D in Figure 7-21. Remove the upper retaining ring

and thrust washer.

To avoid side door damage, use a flat plate for support

when pressing in new bearings.

NOTE

b. When installing new bearings, always press on the

For best results, move the lower retaining ring toward the

bearing OD marked with the number stamp. The

side door. The mainshaft 3rd gear will move down the shaft

number stamp must face toward the outside surface

for easy access to the upper retaining ring.

of the side door. Use a flat plate to support the

inboard side of the side door at the bearing bores.

9. Remove the mainshaft 3rd gear.

NOTE

10. Remove the thrust washer and lower retaining ring.

Note that one side of the retaining rings are beveled. Always

install the ring with the beveled side opposite the bearing.

11. See E in Figure 7-21. Gently pull apart the split cage

Side doors using the beveled retaining rings are marked with

bearing and remove.

a “drill-point” hole between the bearing bores. See Figure 7-

23.

12. Leave both the mainshaft and countershaft 1st gears

and the mainshaft and countershaft 4th gears on their

c. Install new retaining rings with the flat side in

respective shafts.

towards the bearing, the beveled side out.

7-16

2005 Touring: Transmission

HOME

Install a new retaining ring in the groove closest to the

ASSEMBLY

side door end of the mainshaft. Slide the thrust washer

onto the side door end of the mainshaft until it contacts

the retaining ring. Lightly coat split cage bearing with oil

1WARNING

and install in the mainshaft race next to the thrust

Always wear proper eye protection when installing re-

washer.

taining rings. Use the correct retaining ring pliers. Verify

See Figure 7-22. Install mainshaft 4th gear over the split

that the tips of the pliers are not damaged or excessively

cage bearing with the shifter dogs up. From the opposite

worn. Slippage may propel the ring with enough force to

end of the shaft, slide on the mainshaft 1st gear with the

cause eye injury.

shifter fork groove facing the side door end of the shaft.

Install a new retaining ring in the groove closest to the

1WARNING

side door end of the countershaft. Slide the thrust

Always use new retaining rings when assembling the

washer onto the side door end of the countershaft until it

mainshaft and countershaft. Reusing retaining rings can

contacts the retaining ring. Lightly coat split caged bear-

cause the transmission to become “locked” during vehi-

ing with oil and install in the countershaft race next to the

cle operation, a situation which could result in death or

thrust washer.

serious injury.

See Figure 7-22. Install countershaft 1st gear over the

NOTE

split caged bearing with the taper facing down (flat side

Use the TRANSMISSION SHAFT RETAINING RING PLI-

up). From the same end of the shaft, slide on the coun-

ERS, Part No. J-5586, to install all mainshaft and counter-

tershaft 4th gear so that the sleeve contacts the taper of

shaft retaining rings.

the countershaft 1st gear.

8255

MAINSHAFT

COUNTERSHAFT

Retaining Ring

Groove

Split Cage

Bearing Race

Retaining Ring

Groove

Taper

Countershaft 1st

Mainshaft 1st

Shifter Fork Groove

Sleeve

Mainshaft 4th

Countershaft 4th

Shifter Dogs

Figure 7-22. Install Mainshaft and Countershaft 1st and 4th Gears

7-18

2005 Touring: Transmission

HOME

5. See Figure 7-25. Slide the spacers onto the shafts with

the tapered side facing the side door end. Note that the

mainshaft spacer has a shoulder while the countershaft

Retaining

spacer does not.

Locknut

Ring

Bearing

CAUTION

Failure to support the inner races while pressing shafts

through the side door bearings will result in bearing

damage.

6. Place the side door in an arbor press. Support the inner

bearing races with a suitable socket. Starting with the

mainshaft, press the shafts into the bearings. With the

shafts properly pressed into the side door, the spacers

will have no end play. Be sure to install the mainshaft to

Drill Point

the left of the fork shaft hole (when viewing the side door

from the top).

7969

7. Install a spacer and locknut on the threaded end of each

shaft and tighten the nuts until finger tight. See Figure 7-

23. Final tightening is performed under INSTALLATION,

Figure 7-23. Side Door Bearings

steps 4 and 5.

8256

MAINSHAFT

COUNTERSHAFT

Retaining Ring

Countershaft 5th

Countershaft 2nd

Mainshaft 2nd

Split Cage Bearing

Retaining Ring

Thrust Washer

Retaining Ring

Mainshaft 3rd

Countershaft 3rd

Split Cage Bearing

Retaining Ring

Thrust Washer

Retaining Ring

Countershaft 1st

Split Cage Bearing

Mainshaft 1st

Retaining Ring

Thrust Washer

Mainshaft 4th

Countershaft 4th

Split Cage Bearing

Figure 7-24. Completed Side Door Assembly

2005 Touring: Transmission

7-19

HOME

f1103axx

Side door

Gasket

Mainshaft spacer

Countershaft spacer

Mainshaft

Countershaft

Spacer (2)

Locknut (2)

Bearings, one-piece

split cage (4)

10.

Mainshaft 4th gear

11.

Thrust washer (5)

12.

Retaining ring (6)

13.

Mainshaft 1st gear

14.

Countershaft 4th gear

15.

Retaining ring

16.

Countershaft 1st gear

17.

Countershaft 3rd gear

18.

Mainshaft 3rd gear

19.

Countershaft 2nd gear

20.

Thrust washer (2)

21.

Countershaft 5th gear

22.

Mainshaft 2nd gear

23.

Push rod

24.

Push rod - left side

25.

Clutch release bearing

Figure 7-25. Side Door, Mainshaft and Countershaft Assembly (Exploded View)

See Figure 7-24. Install countershaft 3rd gear with the

11. Slide the countershaft 5th gear down the countershaft

shifter fork groove facing opposite the side door.

until it contacts the countershaft 2nd gear. Install a new

retaining ring in the groove above the countershaft 5th

Install a new retaining ring in the groove just above the

gear.

mainshaft 1st gear. Slide a thrust washer down the

mainshaft until it contacts the retaining ring. Lightly coat

12. Install the mainshaft

2nd gear on the shaft with the

split caged bearing with oil and install in the mainshaft

shifter fork groove towards the side door.

race next to the thrust washer. Place mainshaft 3rd gear

over the bearing. Install a second thrust washer and a

The final assembly appears as shown in Figure 7-24.

new retaining ring above the gear

NOTE

10.

Install a new retaining ring in the groove above the coun-

Install the main drive gear, if removed. See Section 7.7 MAIN

tershaft 3rd gear. Slide a thrust washer down the coun-

DRIVE GEAR/BEARING, INSTALLATION.

tershaft until it contacts the retaining ring. Lightly coat

split caged bearing with oil and install in the countershaft

race next to the thrust washer. Install the countershaft

2nd gear over the bearing with the shifter dogs facing

the side door end of the shaft.

7-20

2005 Touring: Transmission

HOME

With the transmission locked, tighten the mainshaft and

L = 5/16 Inch S = 1/4 Inch

countershaft locknuts to 45-55 ft-lbs (61-75 Nm). See

Figure 7-23.

Install the oil slinger assembly (with two-piece push rod

and clutch release bearing components).

Install shifter cam and fork assemblies. See Section 7.4

SHIFTER CAM ASSEMBLY/SHIFTER FORKS,

ASSEMBLY.

Install the bearing inner race on the transmission main-

shaft. See Section 6.5 PRIMARY CHAINCASE, MAIN-

SHAFT BEARING INNER RACE, INSTALLATION.

10.

Install the starter and oil filler spout. See Section 5.4

STARTER, INSTALLATION, steps 1-3 and 5-7.

11.

Install the primary chaincase and starter jackshaft

assembly. Install the clutch assembly, primary chain, and

7969

compensating sprocket components. Install the primary

chaincase cover. See Section 6.5 PRIMARY CHAIN-

Figure 7-26. Side Door Screw Size and Torque Sequence

CASE, INSTALLATION.

12.

Install the exhaust system. See Section 3.8 INSTALL-

INSTALLATION

ING ENGINE IN CHASSIS, steps 46-52.

1. Verify that the two locating dowels are in place on the

right side of the transmission case. Hang a new gasket

on the dowels.

2. Squirt a liberal amount of clean transmission lubricant

into the main drive gear to prelube needle bearings.

Install the assembled side door in the transmission case.

See Figure 7-19.

3. Install the four 5/16 inch screws (with flat washers) to

fasten transmission exhaust bracket and bottom of side

door to the transmission case. Install the two 1/4 inch

screws to fasten the top of the side door to the transmis-

sion case. Alternately tighten six screws until snug.

4. Resetting the torque wrench as necessary, tighten the

four 5/16 inch screws to 13-18 ft-lbs (17.6-24.4 Nm) and

the two 1/4 inch screws to 84-132 in-lbs (9.5-14.9 Nm)

in the sequence shown in Figure 7-26.

5. Lock the transmission. This can be accomplished by

manually engaging the shifter dogs of any two gears

(mainshaft or countershaft) with the shifter dogs of an

adjacent gear and then turning the mainshaft locknut

counterclockwise.

2005 Touring: Transmission

7-21

HOME

MAIN DRIVE GEAR/BEARING

7.7

PRELIMINARY INSTRUCTIONS

NOTE

Leave the transmission case in the frame unless the case

itself requires replacement. For illustration purposes, some

photographs may show the case removed.

Remove the exhaust system in two sections. See Sec-

tion 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-

Remove the shifter cam and shifter fork assemblies. See

Section

7.4 SHIFTER CAM ASSEMBLY/SHIFTER

FORKS, DISASSEMBLY.

1. Cross Plate

Hex Nut

12 Inch Bolt

8 Inch Bolt

Remove the primary chaincase cover. Remove the

Driver

Backing Plate

clutch assembly, primary chain, and compensating

Nice Bearing

Installer Cup

sprocket components. Remove the starter jackshaft

Flat Washer

assembly and primary chaincase. See Section 6.5 PRI-

MARY CHAINCASE, REMOVAL.

Figure 7-28. Main Drive Gear/Bearing Remover/Installer

Remove the starter. See Section

5.4 STARTER,

(Part No. HD-35316B)

REMOVAL, steps 6-11.

Moving to rear wheel, remove E-clip and loosen hex nut

See Figure 7-27. Remove the six socket head screws

on right side of axle. Moving to left side, turn adjuster

(bottom four with flat washers) to free both the side door

cam in a counterclockwise direction until belt tension is

and transmission exhaust bracket from the transmission

relieved. Remove the belt from the transmission

case. Pull the side door, mainshaft and countershaft

sprocket.

from the transmission case as a single assembly.

Remove the bearing inner race from the transmission

Remove and discard the door gasket.

mainshaft. See Section

6.5 PRIMARY CHAINCASE,

MAINSHAFT BEARING INNER RACE, REMOVAL.

NOTE

DO NOT USE A HAMMER TO REMOVE THE SIDE DOOR.

If the side door sticks or binds on the locating dowels, gently

pry open using the indents at each side of the door. See Fig-

7970

ure 7-27. Exercise caution to avoid damaging paint.

Remove the two socket screws and lockplate to free the

sprocket nut. Remove the sprocket nut. Use an air

impact wrench for best results.

NOTE

The transmission sprocket nut has left handed threads. Turn

the nut clockwise to remove from the main drive gear.

Remove the transmission sprocket.

REMOVAL

Obtain the MAIN DRIVE GEAR/BEARING REMOVER/

INSTALLER (HD-35316B). See Figure 7-28.

Side

Rear

Door

Indent

Obtain two screws with flat washers not provided with

tool. One screw must be 1/4-20 x 1 inch, and the other

Figure 7-27. Remove Transmission Side Door

must be 5/16-18 x 1-1/2 inch.

2005 Touring: Transmission

7-23

HOME

8. Holding head of bolt on right side of transmission case,

9443

turn hex nut on left side in a clockwise direction until

main drive gear is free.

9. Remove tool. Remove main drive gear from inside

transmission case.

10. On left side of transmission case, pull spacer from bore

of large oil seal.

11. Remove quad seal from either bevel on spacer or shoul-

der on main drive gear. Discard quad seal.

NOTE

Always replace the main drive gear bearing when the main

drive gear is removed. The bearing will be damaged during

the removal procedure.

Figure 7-29. Main Drive Gear Removal

(Right Side)

1WARNING

9444

Always wear proper eye protection when removing

retaining rings. Use the correct retaining ring pliers. Ver-

ify that the tips of the pliers are not damaged or exces-

sively worn. Slippage may propel the ring with enough

force to cause eye injury.

12. Remove retaining ring from groove in bearing bore.

13. From inside transmission case, use a block of wood and

rubber mallet to gently tap bearing (and large oil seal)

towards the outside. Discard bearing and large oil seal.

CLEANING AND INSPECTION

Clean all parts in solvent except the transmission case

and needle bearings. Blow dry with compressed air.

Figure 7-30. Main Drive Gear Removal

(Left Side)

CAUTION

Do not clean the transmission case and needle bearings.

With the stamp “this side out” facing outboard and the

Normal cleaning methods will wash dirt and other con-

script right side up, fasten cross plate to right side of

taminants into the bearing case and behind the needle

bearings leading to bearing failure.

transmission case using second most rearward set of

holes in the side door flange. Install the 1/4-20 x 1 inch

Inspect the main drive gear for pitting and wear. Replace

screw (with flat washer) in the top flange hole, the 5/16-

if necessary.

18 x 1-1/2 inch screw (with flat washer) in the bottom

Inspect the needle bearings inside the main drive gear.

flange hole. Alternately tighten screws until snug.

Replace the needle bearings if the mainshaft race is pit-

Slide 12 inch bolt through center hole in cross plate until

ted or grooved.

threaded end exits left side of transmission case. See

Replace the sprocket if teeth are cracked or worn. See

Figure 7-29.

Section 6.4 SECONDARY DRIVE BELT AND SPROCK-

ETS, TRANSMISSION SPROCKET, for more informa-

On left side of transmission case, slide driver over end of

tion.

bolt with the side stamped “S” facing the transmission

case.

Sparingly apply graphite lubricant to threads of bolt to

Needle Bearing Replacement

ensure smooth operation and prolong service life.

NOTE

Install Nice bearing, flat washer and hex nut on bolt. See

If the main drive gear needle bearings and/or small oil seal

Figure 7-30.

need to be replaced, proceed as follows.

7-24

2005 Touring: Transmission

HOME

8254

Needle

Ram

Bearing

Installer

Small

0.080 In. Step

Oil Seal

0.315 In. Step

Outer

Needle

Bearing

Main Drive

Gear

8252

Figure 7-32. Press Small Oil Seal into Main Drive Gear

Figure 7-31. Press Clutch Side Needle Bearing into

Main Drive Gear

8253

Inner

Pull small oil seal from splined end of main drive gear.

Needle

Use a seal remover or rolling head pry bar for best

Bearing

results.

0.080 In. Step

Remove needle bearings using a bushing/bearing puller

or a suitable straight-thru press tool.

Obtain the MAIN DRIVE GEAR NEEDLE BEARING

AND SMALL OIL SEAL INSTALLER (HD-37842A).

With the splined side up, center main drive gear under

ram of arbor press.

Start new outer (clutch side) needle bearing into splined

end.

Insert the 0.315 inch step end of tool into needle bear-

ing.

Apply pressure until shoulder on tool makes light contact

Figure 7-33. Press Transmission Side Needle

with the gear. See Figure 7-31. Remove tool.

Bearing into Main Drive Gear

Lightly apply Loctite RETAINING COMPOUND No. 609

to OD of new small oil seal.

With the lip garter spring side down, start oil seal into

12.

Turn the main drive gear over so that the gear side is up.

splined end.

13.

Start new inner (transmission side) needle bearing into

10.

Turn the tool over and insert the 0.080 inch step end into

gear end.

oil seal.

11.

Apply pressure until shoulder on tool makes light contact

14.

Insert the 0.080 inch step end of tool into needle bear-

with the gear. See Figure 7-32. Remove tool.

ing.

NOTE

15.

Apply pressure until shoulder on tool makes light contact

An alternative method is provided which allows the small oil

with the gear. See Figure 7-33. Remove tool.

seal to be pressed into place after installation of the main

drive gear. For more information, see FINAL INSTRUC-

TIONS, step 14.

2005 Touring: Transmission

7-25

Harley Davidson 2005 touring models. Service repair manual - page 21