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Harley Davidson Sportster Models 2009. Service Repair Manual - page 65

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21.

11.

Damper spring

Diaphragm spring

Spring

22.

12.

Lockplate

Damper spring seat

Retaining ring

13.

23.

Release plate

Nut

Mainshaft nut

24.

14.

Washer

Retaining ring

Outer ramp

25.

15.

Coupling

Clutch hub

Bearing

16.

26.

Adjusting screw

Ball (3)

Inner thrust washer

27.

17.

Needle bearing inner race

Pressure plate

Inner ramp

28.

18.

Retaining ring

Needle bearing

Friction plate, fiber (7)

19.

29.

Steel plate (7)

Retaining ring

Clutch shell and sprocket

30.

20.

10.

Outer thrust washer

Friction plate, narrow, fiber

Spring seat

Figure 5-21. Clutch Assembly: XR Models

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2009 Sportster Service: Drive/Transmission 5-21

REMOVAL

TOOL NAME

PART NUMBER

SPROCKET LOCKING LINK

HD-38362

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)

Disconnect negative (-) battery cable from stud on engine
crankcase behind starter motor assembly. See

1.17 BATTERY MAINTENANCE

Open left side cover. See

2.20 LEFT SIDE COVER

Remove positive (+) battery cable from battery positive
(+) terminal. See

1.17 BATTERY MAINTENANCE

Remove primary cover and discard primary cover gasket.
See

5.3 PRIMARY CHAIN ADJUSTER

NOTES

•

See

Figure 5-22

. Make sure not to position the sprocket

locking link (1) too close to the shifter shaft (2). If the
sprocket locking link contacts the shifter shaft while you
are exerting force to loosen the engine sprocket bolt,
damage to the shifter shaft and/or the engine crankcase
may result.

•

The engine sprocket bolt is a single-use fastener and must
be replaced with a new bolt whenever it is removed.

See

Figure 5-22

. Install SPROCKET LOCKING LINK (Part

No. HD-38362). Remove and discard the engine sprocket
bolt. Do not remove engine sprocket at this time.

See

Figure 5-21

. Remove large retaining ring (12).

Remove adjusting screw assembly (13, 14, 15 and 16)
from pressure plate (17).

NOTE

Transmission mainshaft nut (23) has left-hand threads. Turn
nut clockwise to loosen and remove from mainshaft.

Remove nut (23) and spring washer (24). Remove the
clutch assembly, primary chain and engine sprocket from
the vehicle as an assembly.

Inspect primary chain. If damaged or excessively worn,
remove it from engine sprocket and clutch assembly and
replace it with a new one.

Inspect stator and rotor. See

6.20 CHARGING SYSTEM

Replace damaged parts as necessary.

NOTE

If replacement of primary chain is the only service work
required, proceed directly to

5.6 PRIMARY DRIVE AND

CLUTCH: XR MODELS, Installation

. Skip Step 1 of that pro-

cedure and begin with the NOTE preceding Step 2.

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Sprocket locking link

Shifter shaft

Figure 5-22. Loosen Engine Sprocket Bolt

DISASSEMBLY

TOOL NAME

PART NUMBER

CLUTCH SPRING FORCING SCREW

HD-38515-91

SPRING COMPRESSING TOOL

HD-38515-A

See

Figure 5-21

. With clutch assembly removed from

primary chaincase, install adjusting screw assembly (13,
14, 15 and 16) into pressure plate (17), noting that two
tabs on perimeter of release plate (13) must be inserted
into corresponding recesses in pressure plate. Secure the
adjusting screw assembly with retaining ring (12).

Disassemble clutch using a spring compressing tool. The
diaphragm spring is compressed and, if removed without
proper tools can fly out, which could result in death or
serious injury. (00292a)

See

Figure 5-23

.Thread the CLUTCH SPRING FORCING

SCREW (Part No. HD-38515-91) onto the clutch adjusting
screw. Place the bridge of SPRING COMPRESSING
TOOL (Part No. HD-38515-A) against diaphragm spring.
Thread the tool handle onto end of forcing screw.

NOTE

See

Figure 5-21

. Turn compressing tool handle only enough

to remove retaining ring (9) and spring seat (10). Excessive
compression of diaphragm spring could damage clutch pres-
sure plate.

See

Figure 5-21

. With a wrench on the clutch spring for-

cing screw flats to prevent the forcing screw from turning,
turn handle clockwise until tool relieves pressure on
retaining ring (9) and spring seat (10).

Remove and discard retaining ring. Remove spring seat
from the groove in clutch hub prongs. Remove the dia-
phragm spring (11), pressure plate (17), adjusting screw
components (13, 14, 15 and 16) and compressing tool as
an assembly.

Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the clutch

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5-22 2009 Sportster Service: Drive/Transmission

adjusting screw. Remove spring seat and diaphragm
spring from pressure plate assembly.

Remove retaining ring (12) and adjusting screw assembly
from pressure plate. If necessary, disassemble adjusting
screw assembly. See

5.6 PRIMARY DRIVE AND

CLUTCH: XR MODELS, Adjusting Screw Disas-
sembly/Assembly

Remove the clutch pack from the clutch hub. The clutch
pack consists of seven friction (fiber) plates (18), seven
steel plates (19), one narrow friction plate (20), one
damper spring (21) and one seat (22).

sm05560

Tool handle

Washer

Bearing

Bridge

Forcing screw

Diaphragm spring

Snap ring

Figure 5-23. Compressing Diaphragm Spring: XR Models

CLUTCH PACK CLEANING AND
INSPECTION

Separate the pack into the following components:

Seven fiber plates.

Seven steel plates.

One narrow fiber plate.

One damper spring.

One damper spring seat.

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 fiber (friction)
plates and needle bearing in the clutch hub/shell. Blow
dry with compressed air.

Examine the clutch components as follows:

Check all clutch plates for wear and discoloration.

Inspect each steel (drive) plate for grooves.

Place each steel plate on a flat surface. Using a feeler
gauge, check for flatness in several places. Replace
any plates that are damaged or are warped more than
0.006 in. (0.15 mm).

Inspect the damper spring for cracks or distortion. Install
a new spring if either condition exists.

See

Figure 5-24

. Check fiber plates for thickness.

Wipe the lubricant from the eight fiber plates (7 regular
and 1 narrow) and stack them on top of each other.

Measure the thickness of the eight stacked fiber plates
with a dial caliper or micrometer. The minimum
thickness must be 0.661 in. (16.789 mm).

If the thickness is less than specified, discard the fiber
plates and steel plates. Install a new set of both fric-
tion and steel plates.

See

Figure 5-25

. Inspect primary chain sprocket (1) and

the starter ring gear (2) on the clutch shell. If either
sprocket or ring gear are badly worn or damaged, replace
the clutch shell.

Inspect slots that mate with the clutch plates on both clutch
shell (4) and hub (3). If slots are worn or damaged, replace
shell and/or hub.

sm00283

Figure 5-24. Measuring Friction Plates

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2009 Sportster Service: Drive/Transmission 5-23

sm00284

Primary chain sprocket

Starter ring gear

Slots on clutch hub

Slots on clutch shell

Figure 5-25. Checking Clutch Shell (Shell Removed from

Primary Shaft)

ADJUSTING SCREW
DISASSEMBLY/ASSEMBLY

See

Figure 5-26

. Remove adjusting screw assembly.

Remove large retaining ring.

Remove adjusting screw assembly from pressure
plate.

If necessary, disassemble adjusting screw assembly.

Remove and discard small retaining ring (6).

Separate the adjusting screw (8) from the bearing (7)
and release plate (5).

Remove bearing (7) from release plate (5).

Replace components as required and reassemble
adjusting screw assembly in reverse order.

Install adjusting screw assembly into pressure plate.

See

Figure 5-41

. Align two tabs on perimeter of

release plate with corresponding recesses (3) in
pressure plate.

Secure the adjusting screw assembly with new
retaining ring.

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Retaining ring

Spring seat

Diaphragm spring

Retaining ring

Release plate

Retaining ring

Bearing

Adjusting screw

Pressure plate

Figure 5-26. Adjusting Screw Assembly

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Retaining ring

Bearing and release plate

Retaining ring

Adjusting screw

Figure 5-27. Adjusting Screw Assembly

CLUTCH SHELL/HUB INSPECTION

Inspect engine sprocket for damage or excessive wear.
Replace as required.

Disassemble adjusting screw assembly and inspect
bearing, release plate, and adjusting screw. See

5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS,
Adjusting Screw Disassembly/Assembly

Remove clutch hub from clutch shell. Inspect primary chain
sprocket and the starter ring gear on the clutch shell.

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5-24 2009 Sportster Service: Drive/Transmission

Inspect slots that mate with the clutch plates on both clutch
shell and hub.

See

Figure 5-28

. Inspect the clutch shell compensating

spring set.

NOTE

It is possible for the compensating springs to float and move
during inspection. This condition is normal.

See

Figure 5-29

. Inspect clutch shell needle bearing for

smoothness. Rotate the clutch shell while holding the
clutch hub. If bearing is rough or binds, it must be replaced.
See

5.6 PRIMARY DRIVE AND CLUTCH: XR MODELS,

Clutch Shell Bearing Replacement

See

Figure 5-30

. Inspect clutch shell bearing inner race

on the back side of the clutch hub for pitting and wear. If
the inner race shows any signs of damage, the complete
hub assembly must be replaced.

Replace damaged parts as necessary.

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Figure 5-28. Compensating Spring Set

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Figure 5-29. New Needle Bearing in Clutch Shell

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Figure 5-30. Clutch Hub Bearing Race

CLUTCH SHELL BEARING REPLACEMENT

TOOL NAME

PART NUMBER

CLUTCH SHELL BEARING
REMOVER/INSTALLER

B-45926

NOTE

The clutch shell uses a caged needle bearing that corresponds
to an inner race installed on the clutch hub.

See

Figure 5-32

. Place clutch shell on support blocks with

sprocket side facing up.

NOTE

The CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926) is clearly marked for removal and installation
purposes.

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2009 Sportster Service: Drive/Transmission 5-25

See

Figure 5-32

. Insert removal end of tool into bearing

assembly and remove bearing from clutch shell.

See

Figure 5-33

. Remove bearing guide from end of

CLUTCH SHELL BEARING REMOVER/INSTALLER (Part
No. B-45926).

Place new needle bearing onto installer end of tool and
insert the bearing guide to prevent the bearing from falling
off during installation and to align bearing with clutch shell.

See

Figure 5-34

. Place clutch shell on support blocks with

sprocket side facing up.

Press bearing into clutch shell until tool bottoms on the
shell. This will be the correct installed height.

sm00294

Removal end of bearing tool

Installation end of bearing tool

Bearing guide, installer

Figure 5-31. Clutch Shell Bearing Remover/Installer

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Figure 5-32. Removing Clutch Shell Needle Bearing

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Place needle bearing on tool in this location

Bearing guide

Figure 5-33. Bearing Installer

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Needle bearing

Figure 5-34. Installing Clutch Shell Needle Bearing

ASSEMBLY

TOOL NAME

PART NUMBER

SPRING COMPRESSING TOOL

HD-38515-A

Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.

See

Figure 5-35

. Install narrow friction plate on the clutch

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

See

Figure 5-36

. Install damper spring seat (5) on clutch

hub so that it seats inboard of narrow friction plate (4).

Install damper spring (1) on clutch hub with the concave
side up (facing opposite damper spring seat).

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5-26 2009 Sportster Service: Drive/Transmission

Install a steel plate and then a friction plate on the clutch
hub. Install six remaining sets in the same manner,
alternating between steel plates and friction plates.

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Narrow plate

Regular plate

Figure 5-35. Friction Plates

Place pressure plate, diaphragm spring, adjusting screw
assembly with new retaining ring and spring seat onto
clutch pack.

Compress diaphragm spring and install retaining ring:

See

Figure 5-37

. Align square openings of pressure

plate and diaphragm spring so that the assembly can
be installed over prongs on clutch hub.

Position spring seat with its larger outer diameter side
toward diaphragm spring.

NOTE

See

Figure 5-38

. Turn compressing tool handle only the

amount required to install spring seat and snap ring.
Excessive compression of diaphragm spring could damage
clutch pressure plate.

See

Figure 5-38

. Install SPRING COMPRESSING

TOOL (Part No. HD-38515-A) onto clutch hub against
diaphragm spring.

Place a wrench on the clutch spring forcing screw
flats to prevent the forcing screw from turning.

Turn compressing tool handle clockwise until dia-
phragm spring compresses just enough to install new
retaining ring into the groove in clutch hub prongs.

With retaining ring fully seated in groove of clutch
hub, carefully loosen and remove compression tool.

NOTE

When the compressing tool is removed, the diaphragm spring
will move outward forcing the spring seat up into the inside of
the retaining ring. The spring seat provides an operating surface
for the diaphragm spring at the same time preventing the
retaining ring from coming out during operation.

sm00286

Damper spring

Clutch hub

Steel plate

Narrow friction plate

Damper spring seat

Clutch shell

Figure 5-36. Clutch Pack Stack-Up (Cut-Away View)

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Diaphragm spring (pressure plate below)

Prongs on clutch hub

Retaining ring

Adjusting screw assembly

Spring seat

Figure 5-37. Spring Seat Installation

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2009 Sportster Service: Drive/Transmission 5-27

sm05560

Tool handle

Washer

Bearing

Bridge

Forcing screw

Diaphragm spring

Snap ring

Figure 5-38. Compressing Diaphragm Spring: XR Models

INSTALLATION

TOOL NAME

PART NUMBER

SPROCKET LOCKING LINK

HD-38362

See

Figure 5-21

. Remove retaining ring (12). Remove

adjusting screw assembly (13, 14, 15, 16) from pressure
plate (17) to allow installation of the transmission mainshaft
nut and washer.

NOTE

Prior to installing engine sprocket bolt and transmission main-
shaft nut, thoroughly clean threads of engine sprocket shaft,
transmission mainshaft and mainshaft nut to remove any oil
that might contaminate and interfere with locking agent.

Thoroughly clean threads of engine sprocket shaft, trans-
mission mainshaft and mainshaft nut to remove any oil.

NOTE

See

Figure 5-39

. Make sure not to position the sprocket locking

link (1) too close to the shifter shaft (2). If the sprocket locking
link contacts the shifter shaft while you are exerting force to
tighten the engine sprocket bolt, damage to the shifter shaft
and/or the engine crankcase may result.

See

Figure 5-39

. Install SPROCKET LOCKING LINK (Part

No. HD-38362) (1).

Install new engine sprocket bolt. Tighten to 155-165 ft-lbs
(210.0-224.0 Nm).

NOTE

See

Figure 5-40

. Washer (2) must be installed with the word

"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.

See

Figure 5-40

. Apply two or three drops of LOCTITE

Threadlocker 262 (red) onto threads on end of transmis-
sion mainshaft. Install spring washer (2) and mainshaft
nut (1) (left-hand threads) on transmission mainshaft.
Tighten nut to 70-80 ft-lbs (95.0-108.6 Nm).

Remove SPROCKET LOCKING LINK.

See

Figure 5-41

. Install adjusting screw assembly in

pressure plate, noting that two tabs on perimeter of release
plate must be inserted into corresponding recesses in
pressure plate. Secure assembly with a new retaining
ring.

Install primary cover using new gasket. See

5.3 PRIMARY

CHAIN ADJUSTER

Adjust primary chain and clutch. See

10. Fill transmission with GENUINE HARLEY-DAVIDSON

FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT. See

1.14 TRANSMISSION LUB-

RICANT

11. Connect battery. See

1.17 BATTERY MAINTENANCE

sm01266

Sprocket locking link

Shifter shaft

Figure 5-39. Tighten Engine Sprocket Fastener (typical)

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Mainshaft nut

Washer

Clutch hub

Figure 5-40. Mainshaft Nut and Washer

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5-28 2009 Sportster Service: Drive/Transmission

sm00288

Adjusting screw assembly

Retaining ring

Tab recesses

Figure 5-41. Clutch Adjusting Screw Assembly and

Retaining Ring

HOME

2009 Sportster Service: Drive/Transmission 5-29

5.7

DRIVE BELT

REMOVAL

XL Models

Remove both mufflers and rear exhaust pipe. See

4.15 EXHAUST SYSTEM: XL MODELS

Models equipped with mid-mount foot controls:
Remove right side rider footrest/brake pedal and mounting
bracket assembly. See

2.40 RIDER FOOT CONTROLS:

XL MODELS EQUIPPED WITH MID-MOUNT CONTROLS

See

Figure 5-42

. Remove screw (6), washer (5) and

exhaust pipe clamp bracket (4). Remove two screws (2,
3). Remove sprocket cover (1).

See

Figure 5-43

. Remove and discard e-clip (1) and loosen

rear axle nut (4). Decrease belt tension by turning the axle
adjuster nut (2) on each side of rear fork an equal number
of turns counterclockwise.

See

Figure 5-44

. Remove right lower shock absorber

screw (2), washer (3) and lock nut (1).

sm01356

Sprocket cover

Screw

Exhaust pipe clamp bracket

Washer

Screw

Figure 5-42. Sprocket Cover: XL Models

sm03591

E-clip

Axle adjuster nut (2)

Axle adjuster (2)

Axle nut

Washer

Protective cap (2)

Figure 5-43. Secondary Drive Belt Adjustment (typical; XL

model shown)

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5-30 2009 Sportster Service: Drive/Transmission

sm01358

Lock nut

Screw

Washer

Belt guard

Screw

Washer

Nut

Debris deflector

Screw with captive washer (3)

10. Rear fork

Figure 5-44. Belt Guard/Debris Deflector: XL Models

Remove nut (7), screw (5) and washer (6) securing front
of belt guard (4) to rear fork (10). Remove belt guard.

Loosen, but do not remove three screws with captive
washers (9) securing debris deflector (8) to rear fork. Slide
debris deflector forward until keyway slots in deflector
clear screw heads. Remove debris deflector.

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)

Remove belt.

XR Models

Remove exhaust system. See

. Remove screws (2, 3, 4). Remove

sprocket cover (1).

See

Figure 5-43

. Remove and discard e-clip (1) and loosen

rear axle nut (4). Decrease belt tension by turning the axle

adjuster nut (2) on each side of rear fork an equal number
of turns counterclockwise.

Remove right lower shock absorber screw, washer and
lock nut. See

2.26 SHOCK ABSORBERS

sm05328

Sprocket cover

Rear screw and washer

Front screw

Lower screw

Figure 5-45. Sprocket Cover: XR Models

Remove belt guard and debris deflector. See

2.24 BELT

GUARD AND DEBRIS DEFLECTOR

Remove belt.

INSTALLATION

XL Models

Install belt onto sprockets.

See

Figure 5-44

. Install belt guard (4). Install screw (5),

washer (6) and nut (7) securing front of belt guard to rear
fork (10). Tighten to 120-180 in-lbs (13.6-20.3 Nm).

Position debris deflector (8) in place on underside of rear
fork (10).

Fit large end of keyway slots in deflector over screw heads
and captive washers (9). Slide deflector rearward to lock
screws in slots. Tighten screws to 36-60 in-lbs (4.1-6.8
Nm).

Install right lower shock absorber screw (2), washer (3)
and lock nut (1). Tighten to 45-50 ft-lbs (61-68 Nm).

See

Figure 5-42

. Install sprocket cover (1). Secure with

two screws (2, 3). Note that long screw goes in top hole,

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2009 Sportster Service: Drive/Transmission 5-31

short screw in bottom hole. Do not tighten screws at this
time.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).

Models equipped with mid-mount foot controls: Install
right side rider footrest/brake pedal and mounting bracket
assembly. See

2.40 RIDER FOOT CONTROLS: XL

MODELS EQUIPPED WITH MID-MOUNT CONTROLS

Install rear exhaust pipe and both mufflers. See

4.15 EXHAUST SYSTEM: XL MODELS

10. Adjust belt tension and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

11. See

Figure 5-43

. Tighten rear axle nut (4) to 95-105 ft-lbs

(129-142 Nm). Install new e-clip (1).

XR Models

Install belt onto sprockets.

Install belt guard and debris deflector. See

2.24 BELT

GUARD AND DEBRIS DEFLECTOR

Install right lower shock absorber screw, washer and lock
nut. Tighten to 45-50 ft-lbs (61-68 Nm). See

2.26 SHOCK

ABSORBERS

See

Figure 5-45

. Install sprocket cover (1). Note that

longer screw goes in top hole, short screw in bottom hole.

Tighten screw (2) to 30-33 ft-lbs (40.7-44.7 Nm)

Tighten screws (3, 4) to 80-120 in-lbs (9.0-13.6 Nm).

Install exhaust system. See

4.16 EXHAUST SYSTEM:

XR MODELS

Adjust belt tension and rear wheel alignment. See

1.16 REAR BELT DEFLECTION

See

Figure 5-43

. Tighten rear axle nut (4) to 95-105 ft-lbs

(129-142 Nm). Install new e-clip (1).

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5-32 2009 Sportster Service: Drive/Transmission

sm02440

Forward bend: 5 in. (127 mm) minimum diameter

Reverse bend: 10 in. (254 mm) minimum diameter

Do not twist

Do not crimp, pinch or kink

Do not pry

Figure 5-46. Proper Drive Belt Handling

IDLER PULLEY: XR MODELS ONLY

Removal

See

Figure 5-47

. Remove sprocket cover (1).

NOTE

It is not necessary to remove the drive belt completely.

Remove tension from drive belt and slide belt off drive
sprocket (5). See

5.7 DRIVE BELT, Removal

NOTE

If exhaust system interference prevents removal, loosen all
exhaust system mount fasteners and flange nuts. Pull exhaust

system away from engine to allow room to remove idler
assembly.

Remove nuts (3) and washers (4). Remove idler pulley
and bracket assembly from vehicle.

Inspect idler pulley (7) by spinning and checking for
bearing wear. See

1.15 REAR BELT AND SPROCKETS,

Inspection

NOTE

The idler pulley bearings can not be replaced separately.

HOME

2009 Sportster Service: Drive/Transmission 5-33

If idler pulley needs replacement, remove fastener (8) and
bushings (2). Discard idler pulley and replace with new
idler pulley (7).

sm05541

Sprocket cover

Bushing (2)

Flanged nut (2)

Washer (2)

Drive sprocket

Idler pulley bracket

Idler pulley

Fastener

Figure 5-47. Drive Belt Idler: XR Models

Installation

See

Figure 5-47

. Install new or existing idler pulley (7), if

removed. Tighten fastener (8) to 70-80 ft-lbs (95-109 Nm).

Install idler pulley and bracket assembly. Install washers
(4) and flanged nuts (3), and tighten to 33-35 ft-lbs (45-47
Nm).

Install drive belt and adjust belt tension and wheel align-
ment. See

1.16 REAR BELT DEFLECTION

Install sprocket cover. Tighten rear (larger) screw to 30-
33 ft-lbs (40.7-44.8 Nm).Tighten forward and lower
(smaller) screws to 80-120 in-lbs (9.0-13.6 Nm).

If loosened, align and tighten exhaust system components.
See

4.16 EXHAUST SYSTEM: XR MODELS

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5-34 2009 Sportster Service: Drive/Transmission

5.8

TRANSMISSION

GENERAL

See

Figure 5-48

. The transmission is a five-speed constant-

mesh type housed in an extension of the crankcase. The
transmission permits the rider to vary the ratio of engine speed-
to-rear driving wheel speed in order to meet the varying condi-
tions of operation.

The transmission is foot-operated by the gear shifter lever,
which transmits the force through a gear shifter shaft. The
shifter shaft actuates a pawl and a shifter fork drum. The shifter
fork drum moves shifter forks, which slide a series of shifter
dogs on the mainshaft and countershaft, into and out of mesh
with the other gears.

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2009 Sportster Service: Drive/Transmission 5-35

{

sm03353

Power flow

Mainshaft

Countershaft

Moves in

Moves out

Countershaft gears

Sliding member

Figure 5-48. Transmission Power Flow

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5-36 2009 Sportster Service: Drive/Transmission

Content .. 63 64 65 66 ..