Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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200

CHAPTER FIVE

PRIMARY CHAINCASE

1. Oil seal

2. Chaincase inner

housing

3. Snap ring

4. O-ring

5. Pin

6. Gasket

7. Bushing

8. Locking tab

9. Bolt

10. Washer

11. Chaincase cover

12. Clutch cover

13. Drain plug

14. Gasket

15. Inspection cover

16. Bearing

b. Remove the clamping bolt (B, Figure 3) and

remove the outer shift lever.

c. Remove the screws and the inspection cover

and gasket

(Figure

4) from the primary

chaincase cover.

4B. On FXDWG models, remove the primary chain

inspection cover and gasket.

5. Remove the bolts and washers securing the

chaincase outer cover (Figure 5) and remove the

chaincase outer cover. Note the location of the two

different length bolts.

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CLUTCH AND PRIMARY DRIVE

201

6. Remove the two round gaskets (Figure 6) in-

stalled between the chaincase outer cover and

chaincase inner housing. The gaskets may stick to

either part.

7. Remove the chaincase outer cover gasket.

8. Remove the dowel pins, if necessary.

Inspection

1. Remove all gasket residue from the chaincase

outer cover (Figure 7) and chaincase inner housing

gasket surfaces.

2. Clean the primary cover in solvent and dry with

compressed air.

3. Inspect the chaincase outer primary cover for

cracks or damage.

4. Inspect the starter jackshaft bushing (Figure 8)

for excessive wear or damage. To replace the bush-

ing, perform the following:

a. Remove the bushing with a blind bearing re-

moval tool.

b. Clean the bushing bore in the housing.

c. Press in the new bushing until its outer sur-

face is flush with the edge of the bushing

bore.

Installation

1. Install two new round gaskets (Figure 6) on the

chaincase outer cover studs.

2. If removed, install the dowel pins (A, Figure 9)

onto the chaincase inner housing.

CAUTION

Harley-Davidson specifies that a new

Print-O-Seal gasket must be installed

every time the chaincase outer cover

is removed.

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202

CHAPTER FIVE

CLUTCH ASSEMBLY

Snap ring

Clutch shell and

sprocket

Bearing

Snap ring

Clutch hub

Clutch nut

Diaphragm spring

seat

Diaphragm spring

Friction disc B

10.

Clutch plates

11.

Friction disc A

12.

Pressure plate

13.

Diaphragm spring

14.

Diaphragm spring

retainer

15.

Bolt

16.

Release plate

17.

Snap ring

18.

Snap ring

19.

Thrust washer

20.

Radial bearing

21.

Oil slinger

22.

Pushrod (right side)

23.

Pushrod (right side

24.

Pushrod (left side)

25.

Locknut

3. Install a new gasket (B, Figure 9) over the locat-

very large. The gasket may shift prior

ing pins and seat it against the gasket surface of the

to installing the cover bolts, so make

chaincase inner housing.

sure the gasket is positioned correctly

while installing the cover bolts in Step

4. Slide the primary cover (Figure 5) over the lo-

cating dowels and seat it flush against the gaskets.

NOTE

5. Install the primary cover bolts and washers (Fig-

The gasket sealing surface is very thin

ure 10) into the correct locations noted during re-

and the overall size of the gasket is

moval. Tighten the primary cover bolts to the

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CLUTCH AND PRIMARY DRIVE

203

c. Install the clamping bolt (B, Figure 3) and

tighten securely.

6B. On FXDWG models, install a new gasket and

the inspection cover onto the primary chaincase

cover. Install the screws and tighten to the specifica-

tion in Table 2.

7. Install the left side footpeg assembly (Figure 2)

and tighten the bolts securely.

8. Refill the primary chaincase with the type and

quantity of oil specified under Primary Chain Lu-

brication in Chapter Three.

9. Connect the negative battery cable as described

in Chapter Eight.

CLUTCH PLATES AND

FRICTION DISCS

This section describes removal, inspection and

installation of the clutch plates. If the clutch re-

quires additional service, refer to Clutch Shell in

this chapter.

Refer to Figure 12.

Removal

NOTE

On models so equipped, always dis-

arm the optional TSSM security sys-

tem prior to disconnecting the battery

or the siren will sound.

1. Disconnect the battery negative lead as de-

scribed in Chapter Eight.

2. Remove the clutch mechanism inspection cover

and O-ring (Figure 13).

3. At the clutch mechanism, loosen the clutch ad-

justing screw locknut (A, Figure 14) and turn the

adjusting screw (B) counterclockwise to allow slack

specification in Table

2. Check that the gasket seats

against the diaphragm spring.

flush around the cover.

4. Remove the primary chaincase outer cover as

described in this chapter.

6A. On all models except FXDWG, perform the fol-

5. Loosen the bolts securing the diaphragm spring

lowing:

retainer (A, Figure 15) in a crisscross pattern. Re-

a. Install a new gasket (Figure 11) and the in-

move the bolts, retainer and diaphragm spring (B,

spection cover (Figure 4) onto the primary

Figure 15).

chaincase cover. Install the screws and

6. Remove the pressure plate (Figure 16).

tighten to the specification in Table 2.

7. Remove the clutch plates and friction discs from

b. Align the mark made in Step 4 Removal and

the clutch shell. After the first six clutch plates and

install the outer shift lever (A, Figure 3) onto

friction discs are removed, carefully remove the re-

inner shift lever shaft.

maining ones with a pick tool.

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204

CHAPTER FIVE

8. Remove the damper spring and damper spring

seat from the clutch shell. Keep all parts in order as

shown in Figure 17.

Inspection

When measuring the clutch components, com-

pare the actual measurements to the specifications

in Table 1. Replace parts that are out of specifica-

tion or show damage as described in this section.

1. Clean all parts in solvent and thoroughly dry

with compressed air.

2. Inspect the friction discs as follows:

NOTE

If any friction disc is damaged or out

of specification as described in the

following steps, replace all of the fric-

tion discs as a set. Never replace only

one or two discs.

a. The friction material used on the friction

discs (Figure 18) is bonded onto an alumi-

num plate for warp resistance and durability.

Inspect the friction material for excessive or

uneven wear, cracks and other damage.

Check the disc tangs for surface damage. The

sides of the disc tangs must be smooth where

they contact the clutch shell fingers; other-

wise, the discs cannot engage and disengage

correctly.

NOTE

If the disc tangs are damaged, inspect

the clutch shell fingers carefully as

described later in this section.

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CLUTCH AND PRIMARY DRIVE

205

b. Measure the thickness of each friction disc

with a vernier caliper (Figure 19). Measure at

several places around the disc.

Inspect the clutch plates (Figure 20) as follows:

a. Inspect the clutch plates for cracks, damage

or color change. Overheated clutch plates will

have a blue discoloration.

b. Check the clutch plates for an oil glaze

buildup. Remove by lightly sanding both

sides of each plate with 400 grit sandpaper

placed on a surface plate or piece of glass.

c. Place each clutch plate on a flat surface and

check for warp with a feeler gauge (Figure

21).

d. The clutch plate inner teeth mesh with the

clutch hub splines. Check the clutch plate

teeth for any roughness or damage. The teeth

contact surfaces must be smooth; otherwise,

the plates cannot engage and disengage cor-

rectly.

NOTE

If the clutch plate teeth are damaged,

inspect the clutch hub splines care-

fully as described later in this section.

Inspect the diaphragm spring (Figure 22) for

cracks or damage.

5. Inspect the diaphragm spring retainer for cracks

or damage. Also check for bent or damaged tabs

(Figure 23).

6. Inspect the pressure plate contact surface (Fig-

ure 24) for cracks or other damage.

7. If necessary, disassemble the pressure plate as

follows:

a. Remove the snap ring and remove the release

plate, left side pushrod and locknut (Figure

25) from the pressure plate.

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206

CHAPTER FIVE

b. Inspect the release plate, left side pushrod and

locknut for wear or damage.

c. Inspect its snap ring groove for damage.

d. Position the release plate with the OUT mark

facing out (Figure 26) and install the assem-

bly into the pressure plate.

e. Install the snap ring and make sure it is cor-

rectly seated in the pressure plate groove.

Installation

NOTE

The clutch assembly (Figure 17) has

nine friction plates, eight steel plates,

one damper spring and one damper

spring seat. Make sure each is in-

stalled. If installing an aftermarket

clutch plate assembly, follow the man-

ufacturer’s instructions for plate

quantity, alignment and installation

sequence.

1. Soak the clutch friction disc and clutch plates in

new primary drive oil for approximately 5 minutes

before installing them.

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CLUTCH AND PRIMARY DRIVE

207

NOTE

There are two different types of clutch

friction discs (Figure 27). The wider

friction disc A is the normal width

disc, while the narrow width friction

disc B is installed first, as it works in

conjunction with the damper spring

and damper spring seat.

2. Install the clutch friction disc B (Figure 28) onto

the clutch shell and clutch hub. Push it on all the

way until it bottoms within the clutch hub.

3. Install the damper spring seat (Figure 29) onto

the clutch hub and push it in until it seats within the

clutch friction disc B.

4. Position the damper spring with the dome side

facing out (Figure 30) and install it onto the clutch

hub against the damper spring seat (Figure 31).

5. Install a clutch plate (Figure 32), then a friction

disc A (Figure 33). Continue to alternately install

the clutch plates and friction discs. The last part in-

stalled is a friction disc A (Figure 34).

6. Make sure the oil slinger assembly (Figure 35)

is in place in the pressure plate. Install the pressure

plate onto the clutch hub (Figure 16).

7. Position the diaphragm spring with the dished

side facing out (Figure 36) and install it onto the

pressure plate (Figure 37). Hold the pressure plate

in place.

8. Position the diaphragm spring retainer with the

finger side (Figure 38) facing in toward the dia-

phragm spring (B, Figure 15). Install the dia-

phragm spring retainer (A, Figure 15) and bolts.

9. Tighten the bolts in a crisscross pattern to the

specification in Table 2.

10. Install the primary chaincase outer cover as de-

scribed in this chapter.

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208

CHAPTER FIVE

COMPENSATING SPROCKET (1999-2000)

1. Bolt

2. Anchor plate

3. Screw

4. Chain tensioner

5. Plate

6. Washer

7. Nut

8. Tensioner pad

9. Washer

10. Lockwasher

11. Bolt

12. Primary chain

13. Spacer

14. Shaft extension

15. Compensating sprocket

16. Sliding cam

17. Cover assembly with

springs*

18. Nut*

*Spacer between No. 17 and

No. 18 for 1999 models not

shown

11. Install the clutch mechanism inspection cover

Refer to Figure 12 (clutch assembly), Figure 39

and O-ring (Figure 13).

(1999-2000 models) and Figure 40 (2001 models).

12. Connect the negative battery cable as described

in Chapter Eight.

NOTE

On models so equipped, always dis-

arm the optional TSSM security sys-

CLUTCH SHELL, COMPENSATING

tem prior to disconnecting the battery

SPROCKET AND PRIMARY

or the siren will sound.

DRIVE CHAIN

Removal

1. Disconnect the negative battery cable from the

battery as described in Chapter Eight

This procedure describes clutch shell, primary

chain and engine sprocket removal. These compo-

2. Remove the primary chaincase outer cover as

nents must be removed as an assembly.

described in this chapter.

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CLUTCH AND PRIMARY DRIVE

209

COMPENSATING SPROCKET (2001)

1. Bolt

2. Anchor plate

3. Screw

4. Washer

5. Nut

6. Primary chain

7. Chain tensioner

8. Pad

9. Snap ring

10. Spacer

11. Shaft extension

12. Compensating sprocket

13. Sliding cam

14. Cover assembly with

springs*

15. Nut*

*Spacer between No. 14 and

No. 15 not shown

3. Remove the diaphragm spring, pressure plate,

clutch plates and friction discs as described in this

chapter.

CAUTION

Do not clamp the special tool too tight

as it may damage the grooves in the

clutch hub.

4A. If the special tool is available, such as the

Grabbit (Figure 41), attach it to the clutch hub to

keep it from turning.

4B. If the special tool is not available, shift the

transmission into fifth gear. Have an assistant apply

the rear brake.

CAUTION

The clutch nut has left-hand threads.

Turn the clutch nut clockwise to

loosen it.

5. Loosen the clutch nut (Figure 42) with an im-

pact wrench. Remove the clutch nut.

6. Loosen the compensating sprocket nut (Figure

43) with an impact wrench.

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210

CHAPTER FIVE

7. Remove the compensating sprocket nut (Figure

43), washer (1999 models), cover (Figure 44) and

sliding cam (Figure 45).

8A. On 1999-2000 models, perform the follow-

ing:

a. Remove the primary chain shoe adjuster

locknut (Figure 46).

b. Remove the compensating sprocket, pri-

mary chain, chain adjuster and clutch as-

sembly (Figure 47) at the same time. See

Figure 48.

8B. On 2001 models, perform the following:

a. Loosen the primary chain shoe adjuster

locknut (A, Figure 49) and push the tensioner

assembly down to relieve tension on the pri-

mary chain.

b. Remove the compensating sprocket, primary

chain and clutch assembly (B, Figure 49) at

the same time. See Figure 50.

9. Remove the shaft extension (Figure 51) and the

spacer (Figure 52).

10. Inspect the various components as described in

this chapter.

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CLUTCH AND PRIMARY DRIVE

211

Installation

1. Remove all threadlocking compound residue

from the crankshaft and mainshaft threads and from

the compensating sprocket nut and the clutch nut.

2. Remove all gasket residue from the inner pri-

mary housing gasket surfaces.

3. Install the spacer (Figure 52) and the shaft ex-

tension (Figure 51) onto the crankshaft.

4A. On 1999-2000 models, perform the following:

a. Assemble the compensating sprocket, pri-

mary chain, chain adjuster and clutch as

shown in Figure 48.

b. Install the compensating sprocket, primary

chain, chain adjuster and clutch as shown in

Figure

47. Insert the chain adjuster bolt

through the chain adjuster hole as shown in

Figure 53.

c. Install the primary chain shoe adjuster

locknut (Figure 46) and tighten finger-tight

at this time.

4B. On 2001 models, perform the following:

a. Assemble the compensating sprocket, pri-

mary chain and clutch as shown in Figure

50.

b. Install the compensating sprocket, primary

chain and clutch as shown in B, Figure 49.

5. Install the compensating sprocket (Figure 45)

and the cover (Figure 44).

6. On 1999 models, install the washer.

7. Install the same tool setup (A, Figure 54) used

during removal or shift the transmission into fifth

gear to prevent the compensating sprocket and

clutch shell from rotating during the following

steps.

8. Apply two drops of ThreeBond TB1360 or an

equivalent to the compensating sprocket nut

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212

CHAPTER FIVE

threads. Install the nut (Figure 43) and tighten

(Figure 55) to the specification in Table 2.

NOTE

The clutch nut has left-hand threads.

Turn the nut counterclockwise to

tighten it.

9. Apply two drops of ThreeBond TB1360 or an

equivalent to the clutch nut threads. Install the nut

(Figure 42) and tighten (B, Figure 54) to the speci-

fication in Table 2.

10. If used, remove the special tool from the clutch

shell.

11. Adjust the primary chain as described in Chap-

ter Three.

12. Install the clutch plates and friction discs, pres-

sure plate and diaphragm spring as described in this

chapter.

13. Install the primary chaincase outer cover as de-

scribed in this chapter.

14. Adjust the clutch as described in Chapter

Three.

15. Connect the negative battery cable to the bat-

tery as described in Chapter Eight.

CLUTCH SHELL, CLUTCH

HUB AND SPROCKET

Inspection

The clutch shell is a subassembly consisting of

the clutch shell, the clutch hub, the bearing and two

snap rings.

1. Remove the clutch shell as described in this

chapter.

2. Hold the clutch shell and rotate the clutch hub by

hand. The bearing is damaged if the clutch hub

binds or turns roughly.

3. Check the sprocket

(A, Figure 56) and the

starter ring gear (B, Figure 56) on the clutch shell

for cracks, deep scoring, excessive wear or heat dis-

coloration.

4. If the sprocket or the ring gear are worn or dam-

aged, replace the clutch shell. If the primary chain

sprocket is worn, also check the primary chain and

the compensating sprocket as described in this

chapter.

5. Inspect the clutch hub for the following condi-

tions:

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CLUTCH AND PRIMARY DRIVE

213

a. The clutch plate teeth slide in the clutch hub

splines (A, Figure 57). Inspect the splines

for rough spots, grooves or other damage.

Repair minor damage with a file or oil stone.

If the damage is severe, replace the clutch

hub.

b. Inspect the clutch hub inner splines (Figure

58) for galling, severe wear or other dam-

age. Repair minor damage with a fine cut

file. If damage is severe, replace the clutch

hub.

c. Inspect the bolt towers and threads (B, Figure

57) for thread damage or cracks at the base of

the tower. Repair thread damage with correct

size metric tap. If the tower(s) is cracked or

damaged, replace the clutch hub.

6. Check the clutch shell. The friction disc tangs

slide in the clutch housing grooves (C, Figure 57).

Inspect the grooves for cracks or galling. Repair mi-

nor damage with a file. If the damage is severe, re-

place the clutch housing.

7. If the clutch hub, the clutch shell or bearings are

damaged, replace them as described in the follow-

ing procedure.

Disassembly/Assembly

Do not separate the clutch hub and shell unless

the bearing or either part is going to be replaced. If

the two parts are separated the bearing will be dam-

aged.

Removal and installation of the bearing re-

quires the use of a hydraulic press.

Refer to Figure 12.

1. Remove the clutch as described in this chapter.

Remove the clutch shell assembly from the primary

drive chain.

2. Remove the snap ring (Figure 59) from the

clutch hub groove.

3. Position the clutch hub and shell with the pri-

mary chain sprocket side facing up.

4. Support the clutch hub and clutch shell in a press

(Figure 60).

5. Place a suitable size arbor in the clutch hub sur-

face and press the clutch hub (A, Figure 61) out of

the bearing.

6. Remove the clutch shell from the press (B, Fig-

ure 61).

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214

CHAPTER FIVE

Flat side against bearing

7. On the inner surface of the clutch shell, remove

the bearing retaining snap ring (Figure 62) from the

groove in the middle of the clutch shell.

CAUTION

Press the bearing out from the pri-

Clutch hub

mary chain sprocket side of the clutch

shell. The bearing bore has a shoulder

Clutch

Press

shell

on the primary chain side.

8. Support the clutch shell in the press with the pri-

mary chain sprocket side facing up.

9. Place a suitable size arbor on the bearing inner

Bearing

race and press the bearing out of the clutch shell

(Figure 63).

10. Thoroughly clean the clutch hub and shell in

solvent and dry with compressed air.

11. Inspect the bearing bore in the clutch shell for

Sleeve

damage or burrs. Clean off any burrs that would in-

terfere with new bearing installation.

12. Support the clutch shell in the press with the

primary chain sprocket side facing down.

shell until it bottoms on the lower shoulder. Press

13. Apply chaincase lubricant to the clutch shell

only on the outer bearing race. Applying force to the

bearing receptacle and the outer surface of the

bearing’s inner race will damage the bearing. Refer

bearing.

to Basic Service Methods in Chapter One for addi-

14. Align the bearing with the clutch shell receptacle.

tional information.

15. Place a suitable size arbor on the bearing outer

16. Position the new snap ring with the flat side

race and slowly press the bearing into the clutch

against the bearing and install the snap ring into the

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CLUTCH AND PRIMARY DRIVE

215

roughly, the bearing was installed incorrectly. Re-

peat this procedure until this problem is corrected.

PRIMARY CHAIN AND

GUIDE INSPECTION

1. Remove the primary chain as described under

the Clutch Shell, Compensating Sprocket and Pri-

mary Drive Chain in this chapter.

2. Clean the primary chain in solvent and dry thor-

oughly.

3. Inspect the primary chain (Figure 66) for exces-

clutch shell groove (Figure 62). Make sure the snap

sive wear, cracks or other damage. If the chain is

ring is seated correctly in the clutch shell groove.

worn or damaged, check both sprockets for wear

17. Press the clutch hub into the clutch shell as fol-

and damage.

lows:

NOTE

If the primary chain is near the end of

CAUTION

its adjustment level or if no more ad-

Failure to support the inner bearing

justment is available, and the adjust-

race properly will cause bearing and

ing guide (Figure 67) is not worn or

clutch shell damage.

damaged, the primary chain is exces-

sively worn. Service specifications for

a. Place the clutch shell in a press. Support the

chain wear are not available.

inner bearing race with a sleeve as shown in

Figure 64.

4. Inspect the adjusting guide

(Figure

67) for

b. Align the clutch hub with the bearing and

cracks, severe wear or other damage. Replace the

slowly press the clutch hub into the bearing

adjusting shoe if necessary.

until the clutch hub shoulder seats against the

bearing inner race.

PRIMARY CHAIN ALIGNMENT

c. Install a new snap ring (Figure 59) into the

clutch hub. Make sure the snap ring is seated

A spacer, installed behind the compensating

correctly in the clutch hub groove.

sprocket, aligns the compensating and clutch

18. After completing assembly, hold the clutch

sprockets. Install the original spacer when reinstall-

shell (A, Figure 65) and rotate the clutch hub (B) by

ing the compensating sprocket, primary chain and

hand. The shell must turn smoothly with no rough-

clutch assembly. However, if the primary chain is

ness or binding. If the clutch shell binds or turns

showing wear on one side, or if new components

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216

CHAPTER FIVE

have been installed that could affect alignment, per-

form the following check.

1. Remove the outer primary cover as described in

this chapter.

2. Adjust the primary chain tension so the chain is

snug against both the compensating sprocket and

clutch shell sprocket.

3. Push the primary chain toward the engine and

transmission (at both sprockets) as far as it will go.

4. Place a straightedge on the primary chain side

plates, close to the compensating sprocket.

5. Measure the distance from the chain link side

plates to the primary chaincase housing gasket sur-

face. Record the measurement.

6. Repeat Steps 4 and 5 with the end of the straight-

edge as close to the clutch sprocket as possible. Re-

cord the measurement.

7. The difference between the

2 measurements

must be within 0.030 in. (0.76 mm) of each other. If

the difference exceeds this amount, replace the

spacer (Figure 52) with a suitable size spacer. Refer

to Table 3 for spacer thickness and part number.

8. To replace the spacer, perform the Clutch Shell,

Compensating Sprocket and Primary Drive Chain

in this chapter.

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CLUTCH AND PRIMARY DRIVE

217

PRIMARY CHAINCASE

1. Oil seal

9. Bolt

2. Chaincase inner housing

10. Washer

3. Snap ring

11. Chaincase cover

4. O-ring

12. Clutch cover

5. Pin

13. Drain plug

6. Gasket

14. Gasket

7. Bushing

15. Inspection cover

8. Locking tab

16. Bearing

9. Install the outer primary cover as described in

5. Check the compensating sprocket inner bushing

this chapter.

(Figure 70) for wear.

10. Check and adjust the primary chain tension as

6. Check the sliding cam inner splines (Figure 71)

described in Chapter Three.

for wear.

7. Check the shaft extension splines for wear or

COMPENSATING SPROCKET

galling.

INSPECTION

8. Check the cover (Figure 72) for damage.

9. Inspect the inner threads (Figure 73) of the nut

Refer to Figure 39 (1999-2000 models) and Fig-

for damage.

ure 40 (2001 models).

10. If any of these components were replaced,

1. Remove the compensating sprocket assembly as

check the primary chain alignment as described in

described in this chapter.

this chapter.

2. Clean all parts in solvent and dry with com-

pressed air.

3. Check the cam surfaces (Figure 68) for cracks,

PRIMARY CHAINCASE

deep scoring or wear.

INNER HOUSING

4. Check the compensating sprocket gear teeth

(Figure 69) for cracks or wear.

The primary chaincase inner housing is bolted to

the engine and transmission. It houses the primary

NOTE

drive assembly, flywheel, starter jackshaft and the

If the compensating sprocket teeth are

mainshaft oil seal and bearing assembly.

worn, check the primary chain and the

clutch shell gear teeth for wear.

Refer to Figure 74.

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218

CHAPTER FIVE

Removal

NOTE

On models so equipped, always dis-

arm the optional TSSM security sys-

tem prior to disconnecting the battery

or the siren will sound.

1. Disconnect the negative battery cable from the

battery as described in Chapter Eight.

2. Remove the primary chaincase outer cover as

described in this chapter.

3. Remove the compensating sprocket, primary

chain and clutch assembly as described in this chap-

ter.

4. Remove the starter motor as described in Chap-

ter Eight.

5. Pry the lockwasher tabs away from the inner pri-

mary housing bolts (Figure 75, typical).

6. Loosen and then remove the five bolts (Figure

76) securing the inner housing to the engine and the

transmission. Discard the lockwashers, as new ones

must be installed.

7. Remove the starter jackshaft assembly from the

inner housing.

8. Tap the inner primary housing loose.

9A. On all models except the FXDWG, carefully

pull the inner housing (A, Figure 77) away from the

engine and transmission. Guide the inner shift shaft

(B, Figure 77) out from the inner housing.

9B. On FXDWG models, remove the inner housing

from the engine and transmission.

10. Remove the O-ring (Figure 78) from the en-

gine crankcase shoulder.

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CLUTCH AND PRIMARY DRIVE

219

Inspection

1. Remove all gasket residue from the inner hous-

ing gasket surfaces (Figure 79).

2. Clean the inner housing in solvent and dry thor-

oughly.

3. Check the inner housing (Figure 80) for cracks

or other damage.

4. Check the starter jackshaft oil seal (Figure 81)

for excessive wear or damage. To replace the oil

seal, perform the following:

a. Note the direction the oil seal lip faces in the

housing.

b. Pack the new oil seal lips with grease.

Inner primary housing

c. Pry the oil seal out of the inner primary hous-

ing.

d. Carefully drive the new oil seal into the hous-

ing until it seats against the housing shoulder

(Figure 82).

5. Inspect the starter jackshaft bushing (Figure 83)

Jackshaft oil

seal

for excessive wear, cracks or other damage. To re-

place the bushing, perform the following:

Shoulder

a. Remove the bushing with a blind bearing re-

moval tool.

b. Clean the bushing bore in the housing.

c. Press in the new bushing until its outer sur-

face is flush with the edge of the bushing

bore.

6. Turn the inner bearing race (Figure 84) by hand.

Replace the bearing as follows:

a. Remove the oil seal (Figure 85) as described

in Step 7.

b. Remove the inner and outer bearing snap

rings (Figure 86).

c. Support the inner primary housing and press

the bearing out.

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 11