Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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260

CHAPTER SIX

bearing. Also apply oil to the nut and threaded shaft

of the installer tool.

117

5. Install the bearing onto the installation tool and

assemble the installation tool following the manu-

facturer’s instructions.

6. Slowly tighten the puller nut to pull the bearing

into the transmission case. Continue until the bear-

45°

ing bottoms in the case.

7. Disassemble and remove the installation tool.

45°

Main Drive Gear Installation

1. Replace the main drive gear bearing and oil seal

as described in the previous section.

2. Install a new snap ring. Position it with the flat

side facing the bearing.

3. Install the snap ring and position the open end

118

within 45° of horizontal at the rear of the transmis-

sion case (Figure 117). Make sure it is fully seated

in the snap ring groove.

4. Install the new oil seal into the case so its closed

side faces out.

5. Apply transmission oil to the bearing bore and to

the outer surface of the main drive gear. Also apply

oil to the nut and threaded shaft of the installer tool.

6. Insert the main drive gear into the main drive

gear bearing as far as it will go. Then hold it in place

and assemble the special tool onto the main drive

gear and transmission case following the manufac-

turer’s instructions.

119

7. Slowly tighten the puller nut to pull the main

drive gear into the bearing in the transmission case.

Continue until the gear bottoms in the bearings in-

ner race.

8. Disassemble and remove the installation tool.

9. Install the spacer into the main drive gear oil seal.

10. Install the transmission shaft assemblies from

the transmission case as described in this chapter.

EXTERNAL SHIFT MECHANISM

3. Remove the screws and the inspection cover and

Removal/Installation

gasket (Figure 119) from the primary chaincase

(FXD, FXDL, FXDS-CON,

cover.

FXDX, FXDXT Models)

4. Remove the primary chaincase cover and inner

housing as described in Chapter Five.

1. Make an alignment mark (A, Figure 118) on the

outer shift lever and the end of the inner shift lever

5. Disconnect the shift rod (A, Figure 120) from

shaft.

the shift rod lever (B, Figure 120) on the transmis-

2. Remove the clamping bolt (B, Figure 118) and

sion case.

remove the outer shift lever.

6. Remove the shift linkage assembly.

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TRANSMISSION

261

4. Disconnect the shift rod from the shift rod lever

120

on the transmission case.

5. Remove the shift linkage assembly.

6. Install by reversing these removal steps.

Removal/Installation

(FXDP Models)

1. Make an alignment mark on the outer shift lever

and the end of the inner shift lever shaft.

2. Remove the clamping bolt and remove the outer

shift lever.

3. Remove the acorn nut and washer securing the

121

shift rod to the inner shift lever and disconnect the

shift rod.

4. Remove the inner shift lever from the shift lever

plate. Do not lose the wave washer on the shaft.

5. Disconnect the shift rod from the shift rod lever

on the transmission case.

6. Remove the shift rod.

7. Install by reversing these removal steps.

TRANSMISSION SIDE COVER

AND CLUTCH RELEASE

122

MECHANISM

Removal

1. Remove the exhaust system.

2. Drain the transmission oil as described in Chap-

ter Three.

NOTE

If the cover is difficult to remove from

the gasket and transmission case, ap-

ply the clutch lever after the mounting

bolts are removed. This will usually

Install by reversing these removal steps.

break the cover loose.

3. Remove the side cover mounting bolts and re-

Removal/Installation (FXDWG Models)

move the side cover (Figure 121). Remove the gas-

ket. Do not lose the locating dowels.

1. Make an alignment mark on the outer shift lever

and the end of the inner shift lever shaft.

4. At the clutch cable in-line adjuster, perform the

2. Remove the clamping bolt and remove the outer

following:

shift lever.

a. Slide the rubber boot (A, Figure 122).

3. Remove the inner shift lever from the right side

b. Loosen the adjuster locknut (B, Figure 122)

foot peg assembly. Do not lose the two bushing

and turn the adjuster (C) to provide as much

sleeves within the foot peg assembly.

slack in the cable as possible.

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262

CHAPTER SIX

Disassembly

123

CLUTCH RELEASE

Refer to Figure 123.

MECHANISM

NOTE

Before removing the snap ring in Step 1,

note the position of the snap ring open-

ing. The snap ring must be reinstalled

with its opening in the same position.

1. Remove the snap ring (A, Figure 124) from the

groove in the side cover.

2. Lift the inner ramp (A, Figure 125) out of the

cover and disconnect it from the clutch cable cou-

pling (B, Figure 125).

3. Remove the clutch cable coupling (A, Figure

126).

4. Remove the inner ramp and balls (B, Figure 126).

5. If necessary, remove the clutch cable (B, Figure

124) from the side cover.

Clutch release cover

Ramp coupling

Outer ramp

Inspection

Balls (3)

Inner ramp

Snap ring

1. Clean the side cover and all components thor-

Gasket

oughly in solvent and dry with compressed air.

2. Check the release mechanism balls and ramp

ball sockets for cracks, deep scoring or excessive

wear (Figure 127).

124

3. Check the side cover (Figure 128) for cracks or

damage. Check the clutch cable threads and the cou-

pling snap ring groove for damage. Check the ramp

bore in the side cover for excessive wear or lips or

grooves that could catch the ramps and bind them

sideways, causing improper clutch adjustment.

4. Replace the clutch cable O-ring if damaged.

5. Replace all worn or damaged parts.

Assembly

1. If removed, screw the clutch cable into the side

cover. Do not tighten the cable fitting at this time.

125

2. Install the inner ramp and balls (B, Figure 126).

Center a ball into each socket.

3. Install the clutch cable coupling onto the clutch

cable as shown in A, Figure 126.

4. Connect the inner ramp onto the clutch cable

coupling (B, Figure 125).

5. Align the inner ramp socket with the balls and

install the inner ramp as shown in Figure 129.

6. Install the snap ring into the side cover groove. Po-

sition the snap ring so that its opening faces to the right

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TRANSMISSION

263

126

130

of the outer ramp tang slot as shown in A, Figure 124.

127

Make sure the snap ring is seated correctly in the

groove.

Installation

1. If removed, install the locating dowels (A, Fig-

ure 130).

2. Install a new gasket (B, Figure 130).

3. Install the side cover (Figure 121) and bolts.

Tighten the bolts in a crisscross patter to the specifi-

cation in Table 3.

4. Refill the transmission with oil as described in

Chapter Three.

128

5. Install the exhaust system as described in Chap-

ter Seven.

6. Adjust the clutch as described in Chapter Three.

TRANSMISSION DRIVE SPROCKET

Removal/Installation

NOTE

It is not necessary to remove the

mainshaft bearing race to remove the

transmission drive sprocket.

129

1. Remove the primary chain case assembly as de-

scribed in Chapter Five.

2. Remove the two Allen bolts (A, Figure 131) and

the lock plate (B).

3. If the drive belt has been removed, install a

sprocket locker tool (JIMS part No. 2260) (Figure

132) onto the transmission drive sprocket, follow-

ing the manufacturer’s instructions.

4A. Shift the transmission into gear.

4B. If the drive belt is still in place, have an assistant

apply the rear brake.

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264

CHAPTER SIX

5. Using a countershaft sprocket nut wrench (JIMS

part No. 946600-37A), install the inner collar (A,

131

Figure 133) onto the mainshaft.

CAUTION

The sprocket nut has left-hand

threads. Turn the tool clockwise to

loosen it in Step 6.

6. Install the wrench onto the nut (Figure 134),

turn it clockwise and loosen the nut.

7. Remove the special tools and the nut (B, Figure

133) from the mainshaft.

8. Carefully remove the transmission drive

sprocket from the mainshaft, being careful to not

132

damage the bearing race.

9. Install by reversing these removal steps while

noting the following:

a. Use the same tool setup used during removal.

b. Apply Loctite TB1360 or an equivalent to the

nut and Allen bolts prior to installation.

c. Locate the nut with the flanged side facing the

drive sprocket.

CAUTION

In substep d, do not tighten the nut

past an additional 45° to align the

lock plate bolt holes or the nut will be

133

damaged.

d. Tighten the nut counterclockwise to the speci-

fication in Table 3. Then tighten an additional

30° until the lock plate holes are aligned.

TRANSMISSION CASE

Transmission case removal is only necessary if it

requires replacement or when performing extensive

frame repair or replacing the frame. All internal

components can be removed with the case in the

frame.

134

Refer to Figure 135.

Removal/Installation

1. Drain the transmission oil and primary chain

case lubricant as described in Chapter Three.

2. Remove the primary chaincase cover as de-

scribed in Chapter Five.

3. Remove the clutch assembly as described in

Chapter Five.

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266

CHAPTER SIX

136

137

4. Remove the transmission side cover and clutch

release mechanism as described in this chapter.

138

5. Remove the primary chaincase inner housing as

described in Chapter Five.

6. Remove the transmission drive sprocket (A, Fig-

ure 136) as described in this chapter.

7. Remove the external shift linkage (A, Figure

137) from the transmission as described in this

chapter.

8. Remove the transmission shaft assemblies as de-

scribed in this chapter.

9. Remove the exhaust system as described in

Chapter Seven.

10. Remove the bolt and washer and nuts securing

the left side exhaust mounting bracket. Remove the

bracket from the transmission case.

11. Remove the starter motor as described in Chap-

ter Eight.

12. Remove the battery and battery case as de-

scribed in Chapter Eight.

20. Move the transmission toward the right side

13. Remove the rear wheel as described in Chapter

and remove the transmission case from the frame.

Nine.

21. Install the transmission case by reversing these

14. Remove the oil pan and baffle (B, Figure 136)

removal steps, while noting the following:

from the bottom of the transmission case as de-

a. Make sure the two locating dowels are in

scribed in this chapter.

place on the engine or transmission case (Fig-

15. Remove the external components of the shift

ure 138).

arm assembly as described in the following proce-

b. Tighten the transmission mounting bolts in a

dure.

crisscross pattern to the specification in Table

16. Support the swing arm, then remove the swing

arm pivot bolt as described in Chapter Eleven.

17. Disconnect the two oil hoses (B, Figure 137)

Shift Arm Assembly

connecting the transmission to the crankcase.

18. Remove the four transmission case-to-engine

Removal/disassembly

mounting bolts (C, Figure 136). There are two bolts

on each side.

Refer to Figure 139 and Figure 140.

19. Move the transmission case to the rear to clear

1. Make an alignment mark on the shift rod lever

the two lower locating dowels.

and the end of the shift shaft lever.

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268

CHAPTER SIX

2. Remove the clamp bolt and remove the shift rod

lever from the shift shaft lever.

141

OIL PAN

3. On 1999-2000 models, loosen the locknut and

back out the adjuster until it clears the centering

plate.

4. Remove the snap ring and washer from the shift

lever shaft.

5A. On 1999-2000 models, perform the following:

a. Withdraw the shift shaft lever, centering plate

and spring out from the inner surface of the

transmission case.

b. Remove the centering plate and spring from

the shift shaft lever.

5B. On 2001 models, withdraw the shift shaft lever,

sleeve and spring out from the inner surface of the

transmission case

NOTE

Proceed with Step 6 only if the compo-

nents require replacement.

6A. On 1999-2000 models, if necessary, remove the

snap ring and washer and remove the shift cam pawl

and spring from the shift shaft lever. The pivot pin is

pressed into the shift shaft lever. If removal is nec-

essary, drive it out with a suitable size punch.

6B. On 2001 models, if necessary, remove the snap

ring and washer and remove the shift cam pawl and

spring from the shift shaft lever.

Gasket

Inspection

Baffle spring

Baffle

1A. On 1999-2000 models, check the shift pawl and

Engine oil drain bolt

centering plate for wear. Replace the pawl if dam-

Oil pan

Bolt

aged. Replace the centering plate if its adjustment

Transmission oil drain

slot is elongated.

bolt

1B. On 2001 models, check the shift pawl for wear.

Plug

Replace the pawl if damaged.

9. O-ring

2. Check the springs for wear or damage. Assem-

ble the pawl and spring on the shift arm pin. If the

spring will not hold the pawl on the cam, replace

ver pivot pin. Secure it with the washer and new

it.

snap ring.

3. Check the shift shaft lever for wear or damage.

1B. On 2001 models, if disassembled, install the

Check the end splines for wear or damage.

shift cam pawl and spring onto the shift shaft. Se-

4. Check the shift rod lever for wear or damage.

cure it with the washer and new snap ring.

Check the internal splines for wear or damage.

2. On 1999-2000 models, install the centering plate

on the shift shaft lever and spring.

3. Install the shift shaft lever assembly into the

Assembly/installation

transmission case.

1A. On 1999-2000 models, if disassembled, install

4A. On 1999-2000 models, align the slot in the cen-

the shift cam pawl and spring onto the shift shaft le-

tering plate with the adjuster.

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TRANSMISSION

269

4B. On 2001 models, align the spring with the

Inspection

screw.

5. Refer to the alignment marks made in Step 1 Re-

1. Clean the oil tank, baffle and spring in solvent

moval/Disassembly and install the shift rod lever

and dry thoroughly.

onto the shift shaft lever. Push it on until the bolt

2. Remove all old gasket residue from the oil tank

hole aligns with the shaft lever groove.

and transmission case gasket surfaces.

6. Install the clamp bolt and tighten to the specifi-

3. Inspect the oil pan for cracks or damage. Replace

cation in Table 3.

if necessary.

OIL PAN

Installation

The oil pan mounts onto the bottom of the trans-

mission case. It can be removed with the transmis-

1. Install a new oil tank gasket on the oil pan.

sion mounted in the frame.

2. Install the baffle and baffle spring into the oil

Refer to Figure 141.

pan.

3. Install the oil pan onto the bottom of the trans-

Removal

mission case, and secure with the ten bolts.

4. Tighten the oil pan mounting bolts securely in a

1. Drain the engine oil as described in Chapter

crisscross pattern.

Three.

5. If necessary, replace the engine oil filter as de-

2. Drain the transmission oil as described in Chap-

scribed in Chapter Three.

ter Three.

6. Refill the oil pan with new engine oil as de-

3. Remove the ten bolts securing the oil pan to the

scribed in Chapter Three.

transmission case.

4. Lower and remove the oil pan baffle and baffle

7. Refill the transmission with new oil as described

spring from the transmission case.

in Chapter Three.

5. Remove the gasket.

8. Start the engine and check for leaks.

Table 1 TRANSMISSION SPECIFICATIONS

Transmission type

Five-speed, constant mesh

Gear ratios

First

3.21

Second

2.21

Third

1.57

Fourth

1.23

Fifth

1.00

Transmission fluid capacity

Oil change

20-24 U.S. oz. (591-709 ml)

Rebuild (dry)

24 U.S. oz. (709 ml)

Table 2 TRANSMISSION SERVICE SPECIFICATIONS

Item

In.

Countershaft

Runout

0.000-0.003

0.00-0.08

Endplay

None

(continued)

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270

CHAPTER SIX

Table 2 TRANSMISSION SERVICE SPECIFICATIONS (continued)

Item

In.

Countershaft (continued)

First gear

Clearance

0.0003-0.0019

0.008-0.048

End play

0.005-0.0039

0.127-0.099

Second gear

Clearance

0.0003-0.0019

0.008-0.048

End play

0.005-0.0440

0.127-1.118

Third gear

Clearance

0.000-0.0080

0.000-0.203

Fourth gear

Clearance

0.000-0.0080

0.000-0.203

End play

0.005-0.0390

0.127-0.991

Fifth gear

Clearance

0.000-0.0080

0.000-0.203

End play

0.005-0.0040

0.127-0.102

Mainshaft

Runout

0.000-0.003

0.00-0.08

Endplay

None

First gear

Clearance

0.000-0.0080

0.000-0.203

Second gear

Clearance

0.000-0.0800

0.000-2.032

Third gear

Clearance

0.0003-0.0019

0.008-0.048

End play

0.0050-0.0420

0.127-1.067

Fourth gear

Clearance

0.0003-0.0019

0.008-0.048

End play

0.0050-0.0310

0.127-0.787

Main drive gear (fifth)

Bearing fit in

transmission case

0.0003-0.0017

0.0076-0.043

Fit in bearing

Tight fit

0.0009

0.023

Loose fit

0.0001

0.0025

Fit on mainshaft

0.0001-0.0009

0.0025-0.023

End play

None

Shifter cam assembly

Right edge of middle cam

groove to right support

block distance

1.992-2.002

50.60-50.85

Shifter cam end play

0.0001-0.004

0.0025-0.10

Shifter forks

Shifter fork-to-cam

groove end play

0.0017-0.0019

0.043-0.048

Shifter fork-to-gear

groove end play

0.0010-0.0011

0.025-0.0279

Shift fork finger thickness

0.165

4.19

Side door bearing

Fit in side door

0.0014-0.0001

0.036-0.0025

Fit on countershaft

Tight fit

0.0007

0.018

Loose fit

0.0001

0.0025

Fit on mainshaft

Tight fit

0.0007

0.018

Loose fit

0.0001

0.0025

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TRANSMISSION

271

Table 3 TRANSMISSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Clutch cable fitting

30-60

3-7

Clutch release

cover screws

84-108

9-12

Mainshaft and

countershaft nuts

45-55

61-75

Shift rod

Locknuts

20-24

27-32

Clamp bolts

18-22

24-30

Shift cam support blocks

84-108

9-12

Top cover screws

84-108

9-12

Transmission main and

countershaft locknuts

at side door

27-33

37-45

Transmission case door

1/4 in. fasteners

84-108

9-12

5/16 in. fasteners

13-16

18-22

Transmission drain plug

14-21

19-28

Transmission mounting

bolts

30-35

41-47

Detent follower bolt (2001)

84-108

9-12

Transmission drive

sprocket

Mounting nut*

Lockplate bolts

84-108

9-12

* Tighten an additional 30°—not to exceed 45°.

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CHAPTER SEVEN

FUEL, EXHAUST AND

EMISSION CONTROL SYSTEMS

The fuel system consists of the fuel tank, fuel

WARNING

shutoff valve, single side-draft carburetor and air

Gasoline is a known carcinogenic, as

filter housing.

well as an extremely flammable liq-

uid, and must be handled carefully.

The emission control consists of the Evaporative

Wear latex gloves to avoid contact. If

Emission Control System on all California models.

gasoline does contact skin, immedi-

This chapter includes service procedures for all

ately and thoroughly wash the area

parts of the fuel system and the air filter backplate.

with soap and warm water.

Air filter service is covered in Chapter Three.

Specifications and jet sizes are in Tables 1-3 at

the end of the chapter.

CARBURETOR OPERATION

Table 1 lists carburetor jet sizes.

Table 2 lists fuel system torque specifications.

An understanding of the function of each of the

Table 3 lists exhaust system torque specifications.

carburetor components and their relation to one an-

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FUEL, EXHAUST AND EMISSION SYSTEMS

273

AIR FILTER

1. Backplate

(international)

2. Grommet (California)

3. Backplate (California)

4. O-ring

5. Gasket

6. Backplate (49-state)

7. Breather hollow bolt

8. Breather hose

9. Gasket

10. Air filter

11. Mounting bracket

12. Torx screws

13. Nut clip

14. Enrichment cable

bracket

15. Cable strap

16. Nut

17. Grommet

18. Bolt

19. Screw

20. Trim

21. Cover

22. Seal

other is a valuable aid for pinpointing a source of

the engine next to the horn opens an enrichment

carburetor trouble.

valve, rather than closing a butterfly in the venturi

The carburetor’s purpose is to supply and atomize

area as on some carburetors. In the open position,

fuel and mix it in correct proportions with air that is

the slow jet discharges a stream of fuel into the car-

drawn in through the air intake. At the primary

buretor venturi to enrich the mixture when the en-

throttle opening (idle), a small amount of fuel is si-

gine is cold.

phoned through the pilot jet by the incoming air. As

The accelerator pump circuit reduces engine

the throttle is opened further, the air stream begins

hesitation by injecting a fine spray of fuel into the

to siphon fuel through the main jet and needle jet.

carburetor intake passage during sudden accelera-

The tapered needle increases the effective flow ca-

tion.

pacity of the needle jet as it is lifted, in that it occu-

pies progressively less of the area of the jet. At full

throttle the carburetor venturi is fully open and the

AIR FILTER BACKPLATE

needle is lifted far enough to permit the main jet to

flow at full capacity.

Routine air filter maintenance is described in

The choke circuit is a starting enrichment valve

Chapter Three.

system in which the choke knob on the left side of

Refer to Figure 1.

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274

CHAPTER SEVEN

Removal

1. Remove the air filter cover screw (A, Figure 2)

and remove the cover (B, Figure 2).

2. Remove the Torx screws and bracket (A, Figure

3) from the air filter element.

3. Gently pull the air filter element away from the

backplate and disconnect the two breather hoses

from the hollow bolts on the backplate. Remove the

air filter element (B, Figure 3).

4. Unscrew and remove the breather hollow bolts

(A, Figure 4) securing the backplate to the cylinder

heads.

5A. On California models, pull the backplate (B,

Figure 4) partially away from the cylinder heads

and the carburetor, then disconnect the evaporation

emission control clean air inlet hose (Figure 5).

5B. On all other models, pull the backplate (B, Fig-

ure 4) away from the cylinder heads and remove it.

6. Remove the carburetor gasket.

Inspection

1. Inspect the backplate (Figure 6) for damage.

2. On California models, make sure the trap door

swings freely (Figure 7).

3. Make sure the breather hollow bolts and breather

hoses (Figure 8) are clear. Clean out if necessary.

Installation

1. Apply a couple dabs of gasket sealer to the new

carburetor gasket and attach it to the backside of the

backplate.

2. Move the backplate into position.

3. On California models, move the backplate part

way into position. Connect the evaporation emis-

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FUEL, EXHAUST AND EMISSION SYSTEMS

275

sion control clean air inlet hose (Figure 5) to the fit-

ting on the backside of the backplate.

4. Position the backplate (B, Figure 4) against the

carburetor and cylinder heads. Make sure the Torx

bolt holes of the gasket and backplate are aligned with

the carburetor. Reposition the gasket if necessary.

5. Install the breather hollow bolts (A, Figure 4)

securing the backplate to the cylinder heads.

Tighten to the specification in Table 2.

6. If removed, install a new gasket (Figure 9) onto

the air filter element.

7. Position the element with the flat side facing

down and attach the breather hoses (Figure 10) to

the backside of the element (Figure 11). If an after-

market air filter element is being installed, position

it onto the backplate following the manufacturer’s

instructions.

8. Move the element into position (B, Figure 3)

and install the mounting bracket (A, Figure 3) and

the Torx screws. Tighten the Torx screws to the

specification in Table 2.

9. Apply a drop of ThreeBond TB1342 (blue) or an

equivalent threadlocking compound to the cover

screw prior to installation.

10. Inspect the seal ring (Figure 12) on the air filter

cover for hardness or deterioration. Replace if

necessary.

11. Install the air filter cover (B, Figure 2) and the

screw (A, Figure 2). Tighten the screw to the speci-

fication in Table 2

CARBURETOR

Removal

1. Remove the air filter and backplate as described

in this chapter.

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276

CHAPTER SEVEN

2. Remove the fuel tank as described in this chapter.

3. Loosen the locknut (A, Figure 13) and discon-

nect the starting enrichment valve cable to the

mounting bracket (B, Figure 13). Move the end of

the cable out of the mounting bracket.

4. There are two different throttle cables. Label the

two cables at the carburetor before disconnecting

them. One is the throttle control cable and the other

is the idle control cable. They are identified as fol-

lows:

a. Throttle control cable: A, Figure 14.

b. Idle control cable: B, Figure 14.

5. At the handlebar, perform the following:

a. Slide the rubber boot off both cables.

b. Loosen both control cable adjuster locknuts (A,

Figure 15), then turn the cable adjusters (B)

clockwise as far as possible to increase slack.

6. Disconnect the fuel supply hose (Figure 16)

from the carburetor fitting.

7. Twist and then pull the carburetor off the seal

ring and intake manifold.

8. Disconnect the vacuum hose (Figure 17) from

the carburetor fitting.

9. Disconnect the throttle control cable (A, Figure

18) and the idle control cable (B) from the carbure-

tor cable guide and the throttle wheel.

10. Drain the gasoline from the carburetor assem-

bly.

11. Inspect the carburetor seal ring (Figure 19) on

the intake manifold for wear, hardness, cracks or

other damage. Replace if necessary.

12. If necessary, service the intake manifold as de-

scribed under Intake Manifold in this chapter.

13. Insert a clean lint-free shop cloth into the intake

manifold opening.

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FUEL, EXHAUST AND EMISSION SYSTEMS

277

Installation

1. If removed, seat the seal ring (Figure 19) onto

the intake manifold. Make sure it is correctly seated

to avoid a vacuum leak.

2. Route the starting enrichment valve cable be-

tween the cylinders and toward its mounting

bracket on the left side.

3. Connect the idle cable (B, Figure 14) to the car-

buretor as follows:

a. The idle cable has the small spring (A, Figure

20) on the end of the cable.

b. Insert the idle cable sheath into the rear cable

bracket guide on the carburetor (B, Figure 20).

c. Attach the end of the idle cable into the throt-

tle wheel (C, Figure 20).

4. Connect the throttle cable (A, Figure 14) to the

carburetor as follows:

a. Insert the throttle cable sheath (A, Figure 18)

into the carburetor front cable bracket guide.

b. Attach the end of the throttle cable into the

throttle wheel (C, Figure 18).

5. Operate the hand throttle a few times, making

sure the throttle wheel operates smoothly. Also

check that both cable ends are seated squarely in

their cable bracket guides and in the throttle wheel.

CAUTION

The carburetor must fit squarely onto

the intake manifold. If misaligned, it

may damage the intake manifold seal

ring, resulting in a vacuum leak.

6. Align the carburetor squarely with the intake

manifold (Figure 21), then push it into the manifold

until it bottoms. Position the carburetor so that it sits

square and vertical with the manifold.

7. Connect the vacuum hose (Figure 17) onto the

carburetor fitting. Make sure it is seated correctly.

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278

CHAPTER SEVEN

CARBURETOR

1. Screw

2. Cover

3. Collar

4. Spring

5. Spring seat

6. Jet needle

7. Vacuum piston

8. Cable sealing cap

9. Cable guide

10. Starting enrichment

cap

11. Spring

12. Starting enrichment

valve

13. Hose clamp

14. Spring

15. Hose

16. Fuel inlet fitting

17. Body

29. Main jet holder

41. Rod

18. Screw

30. Main jet

42. Boot

19. Spring

31. Valve

43. O-ring gasket

20. Screw

32. Float

44. Float bowl

21. Throttle cable bracket

33. Rod

45. Screw

22. Screw and washer

34. Washer

46. Diaphragm

23. Collar

35. Spring

47. Spring

24. Pin

36. Collar

48. O-ring

25. Washer

37. Washer

49. Cover

26. Pilot jet

38. E-clip

50. Washer

27. Float pivot pin

39. Washer

51. Screw

28. Needle jet

40. Pin

52. Lever

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FUEL, EXHAUST AND EMISSION SYSTEMS

279

8. Slide a new hose clamp over the fuel supply

hose, then connect the fuel hose to the hose fitting

on the carburetor (Figure 16).

9. Position the starting enrichment valve cable into

the mounting bracket (B, Figure 13), then tighten

the locknut (A, Figure 13) securely.

10. Before installing the fuel tank, recheck the idle

and throttle cable operation. Open and release the

hand throttle. Make sure the carburetor throttle

valve opens and closes smoothly. Check that both

cables are routed properly. If necessary, adjust the

throttle cables as described in Chapter Three.

11. Install the air filter backplate and air filter as de-

scribed in this chapter.

12. Install the fuel tank as described in this chapter.

13. Start the engine. Allow it to idle and check for

fuel leaks.

14. With the engine idling in NEUTRAL, turn the

handlebar side-to-side. The idle speed must remain

the same. If the idle speed increases while turning the

handlebars, the cables are installed incorrectly or dam-

aged. Remove the fuel tank and inspect the cables.

Disassembly

Refer to Figure 22.

1. Unscrew and remove the starting enrichment

valve and cable (Figure 23).

2. Remove the screw and washer (A, Figure 24) on

the side and the top screw (A, Figure 25) securing

the throttle cable bracket to the carburetor. Remove

the bracket (B, Figure 25).

3. Remove the collar (Figure 26) from the cover.

4. Remove the remaining cover screws (Figure

27). Remove the cover and spring (A, Figure 28).

5. Remove the vacuum piston (B, Figure 28) from

the carburetor housing. Do not damage the jet nee-

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 14