Drive Components 6-Books Pdf

DRIVE COMPONENTS 6
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sm03604 sm02400, Figure 6 6 Remove Drive Components. 2 2 Primary drive locking tool, Figure 6 8 Removing Compensating Sprocket Bolt. 1 Engine sprocket, 2 Primary drive locking tool, 3 Clutch sprocket. 4 Mainshaft nut, Figure 6 7 Removing Clutch Hub Mainshaft Nut 2 Sliding cam. 3 Compensating sprocket, 4 Shaft extension, Figure 6 9 Compensating Sprocket All But FXCW C.
6 4 2008 Softail Service Drive, No HD 47977 must be placed between the teeth of the. engine and clutch sprockets, 1 2 e Tighten compensating sprocket to 65 ft lbs 88 2 Nm. f Loosen compensating sprocket back 90 degrees, 4 6 g Re tighten compensating sprocket to 65 ft lbs 88 2. 7 h Using a grease pencil mark a straight line on the. 8 compensating sprocket bolt continuing the line over. 9 onto the chaincase housing for reference, i Using the marks as a guide turn compensating. sprocket bolt 62 1 degrees, 2 FXCW C see Figure 6 12 Install compensating sprocket.
1 Shaft extension assembly, 2 Large spring washer 2. a Install shaft extension 1 with bearing journal facing. 3 Medium spring washer 2, away from vehicle Apply a thin layer of primary. 4 Small spring washer, chaincase oil to the splines and bearing journal. 5 Sliding cam, 6 Compensating sprocket b Install large spring washers 2 Outer diameter of. 7 Thrust washer spring washers should be contacting each other. 8 Sprocket retainer, c Install medium spring washers 3 Outer diameter of.
spring washers should be contacting each other, Figure 6 10 Compensating Sprocket FXCW C. d Install small spring washer 4 so that outer diameter. will contact sliding cam 5 once installed, INSTALLATION e Install sliding cam with flat face contacting small. spring 4 Lubricate sliding cam ramps with primary, PART NUMBER TOOL NAME chaincase oil. HD 47977 PRIMARY DRIVE LOCKING TOOL, f Place drive components primary chain compensating. NOTE sprocket 6 with text this side out facing away from. motorcycle and clutch assembly into position The, The primary chain compensating sprocket and clutch assembly.
clutch hub and shaft extension are splined so a slight. must be installed as an assembly, rotation of the chain drive will aid installation. 1 All but FXCW C see Figure 6 11 Install compensating. sprocket assembly, When installing sprocket retainer 8 make sure that thrust. a Apply a thin layer of primary chaincase oil to the inner washer 7 does not fall off sprocket retainer or that it does. diameter of the compensating sprocket 3 and the not get pinched between the sprocket retainer and exten. splines of shaft extension 4 Assemble shaft exten sion shaft A small amount of white lithium grease will help. sion compensating sprocket and sliding cam 2 hold the thrust washer to the sprocket retainer. Place primary chain over compensating sprocket, assembly g Install thrust washer 7 and sprocket retainer 8. b Place drive components primary chain compensating NOTES. sprocket assembly and clutch assembly into position When installing bolt 9 make sure the spring washers. The clutch hub and shaft extension are splined so a are properly aligned and that spring nearest rotor assembly. slight rotation of the chain drive will aid installation has not slipped between extension and rotor hub. c Install new bolt 6 and washer 5 hand tight, Clutch hub mainshaft nut has left handed threads so turn. counterclockwise to install, d Clean and prime threads of nut Apply two drops of.
LOCTITE THREADLOCKER 262 red to the threads, of the clutch hub mainshaft nut Start nut onto main. shaft and tighten hand tight, See Figure 6 13 When tightening the compensating. sprocket bolt the PRIMARY DRIVE LOCKING TOOL Part, 2008 Softail Service Drive 6 5. Make sure the thrust washer has not slipped between the 9 See Figure 6 18 Slide wedge 2 of primary chain ten. sprocket and sprocket retainer sioner in direction of arrow until all travel is removed. h Install new bolt 9 by hand and snug against sprocket 10 Push shoe 1 down until it contacts wedge Keep tension. retainer Using a 1 3 4 in box end wrench to hold on shoe so wedge stays in place. crankshaft tighten compensating sprocket to 65 ft, lbs 88 2 Nm 11 See Figure 6 19 Insert cable tie 2 as shown to hold. wedge in place Make sure end of cable tie is located. i Loosen compensating sprocket back 90 degrees below primary chain tensioner If cable tie is installed this. way it will hang below primary cover gasket surface and. j Re tighten compensating sprocket to 65 ft lbs 88 2. serve as a reminder to remove cable tie before installing. primary cover, k Using a grease pencil mark a straight line on the.
compensating sprocket bolt continuing the line over. Primary chain tensioner will not complete chain adjustment. onto the chaincase housing for reference, until vehicle is ridden Vehicle must be test ridden after ten. l Using the marks as a guide turn compensating sioner removal installation to ensure proper adjustment. sprocket bolt 62 1 degrees, 12 See Figure 6 20 Install primary chain tensioner 1 into. m Rotate compensating sprocket to make sure there is place Install chain tensioner fasteners 2 and tighten to. a light pressure on sprocket from the springs no 15 19 ft lbs 20 3 25 8 Nm Remove cable tie. clearance should be felt A slight rotation should be. possible by hand with transmission in neutral, The gasket between the primary chaincase cover and chain. NOTE case must be replaced each time the cover is removed Failure. Clutch hub mainshaft nut has left handed threads so turn to replace this gasket may cause primary chaincase leaks. counterclockwise to install 13 Install primary chaincase cover and fill with lubricant See. n Clean and prime threads of nut Apply two drops of 6 2 PRIMARY CHAINCASE COVER Installation. LOCTITE THREADLOCKER 262 red to the threads, of the clutch hub mainshaft nut Start nut onto main. shaft and tighten hand tight 1, See Figure 6 14 When tightening the clutch hub mainshaft 3.
nut the PRIMARY DRIVE LOCKING TOOL must be placed, between the teeth of the engine and clutch sprockets. 3 Tighten clutch hub mainshaft nut to 70 80 ft lbs 94 9 108 5 4. Nm Remove primary drive locking tool 5, 4 See Figure 6 15 Install release plate 5 with locknut 2. and adjuster screw 3 into clutch hub bore The word. OUT stamped on the release plate should face outward. Wear safety glasses or goggles when removing or 2 Sliding cam. installing retaining rings Retaining rings can slip from the 3 Compensating sprocket. pliers and could be propelled with enough force to cause 4 Shaft extension. serious eye injury 00312a 5 Washer, 5 Inspect retaining ring 4 and replace if necessary Install 6 Bolt. retaining ring in clutch hub bore to lock release plate in Figure 6 11 Compensating Sprocket All But FXCW C. position Verify that the retaining ring is completely seated. in the groove, 6 Adjust clutch See 1 11 CLUTCH Adjustment. Primary chain tensioner is non repairable If tensioner is worn. or damaged assembly must be replaced, 7 See Figure 6 16 Although primary chain tensioner is sold.
as an assembly tensioner parts can be disassembled If. primary chain tensioner becomes disassembled assemble. in order shown, 8 See Figure 6 17 Locate end of spring rod 2 on roll pin. 6 6 2008 Softail Service Drive, sm04526 sm02405, 1 Shaft extension. 2 Large spring washer 2, 3 Medium spring washer 2, 4 Small spring washer. 5 Sliding cam, 6 Compensating sprocket, 7 Thrust washer. 8 Sprocket retainer, 1 Primary drive locking tool, 2 Mainshaft nut.
Figure 6 12 Compensating Sprocket FXCW C, Figure 6 14 Installing Clutch Hub Mainshaft Nut. 1 Bolt 1 Diaphragm spring, 2 Primary drive locking tool 2 Locknut. 3 Adjuster screw, Figure 6 13 Installing Compensating Sprocket Bolt 4 Retaining ring. 5 Release plate, Figure 6 15 Clutch, 2008 Softail Service Drive 6 7. 1 Shoe assembly, 5 Spring rod, Figure 6 16 Primary Chain Tensioner Assembly.
sm02411 sm02413, 1 Primary chain tensioner, 1 Shoe 2 Cable tie. 2 Spring rod, 3 Roll pin Figure 6 19 Securing Primary Chain Tensioner. Figure 6 17 Spring Rod Location, Figure 6 18 Primary Chain Tensioner. 1 Chain tensioner, 2 Chain tensioner fasteners, Figure 6 20 Chain Tensioner. 6 8 2008 Softail Service Drive, PRIMARY CHAINCASE HOUSING 6 4.
REMOVAL CHAINCASE HOUSING Mainshaft Bearing and Lip Seal. in this section, MAINSHAFT BEARING AND LIP SEAL, To prevent accidental vehicle start up which could cause Removal. death or serious injury disconnect negative battery. cable before proceeding 00048a, 1 Disconnect negative battery cable. Wear safety glasses or goggles when removing or, 2 Remove primary chaincase cover See 6 2 PRIMARY installing retaining rings Retaining rings can slip from the. CHAINCASE COVER Removal pliers and could be propelled with enough force to cause. 3 Remove starter See 5 2 STARTER Removal serious eye injury 00312a. 1 Pull lip seal from bearing bore on transmission side of. 4 Remove primary chain clutch and compensating sprocket. primary chaincase Use a seal remover or rolling head pry. See 6 3 DRIVE COMPONENTS Removal, bar for best results. 5 See Figure 6 21 Remove sealing fasteners 5 securing. 2 Remove retaining ring from groove on transmission side. primary chaincase housing 9 to crankcase and transmis. of bearing, sion Discard the crankcase gasket 11 and sealing.
fasteners 5 3 Support inner primary chaincase on transmission side of. sm03677 NOTE, 3 Support inner primary chain case area on transmission side. while pressing bearing out of primary chaincase The force. needed to remove bearing may cause damage to primary chain. 10 4 Place primary chaincase in arbor press Press out bearing. from clutch side applying pressure to the outer race. Installation, 1 Inspect the bearing bore to verify that it is clean and. smooth Install retaining ring in groove on pulley side of. primary chaincase, 2 Place primary chaincase in arbor press with the transmis. sion side up, 6 3 Support the bearing support area on the clutch side of the. 4 5 primary chaincase, 1 Seal Support the bearing support area on clutch side while pressing.
2 Lock ring bearing into bore The force needed to press bearing into. 3 Bearing position may force and unsupported primary chain case to. 4 Dowel pin become damaged, 5 Sealing fastener, 6 Chain tensioner fasteners 4 Apply a thin film of oil to outer diameter of bearing. 7 Drain plug and o ring 5 Applying pressure to the outer race press new bearing. 8 Chain tensioner letter side up into bore until it makes solid contact with. 9 Primary chaincase housing the bearing support area. 10 Shifter shaft bushing, 11 Crankcase gasket 6 See Figure 6 22 Retaining ring 1 must be oriented as. shown to prevent blocking of oil passage 2 Install. Figure 6 21 Primary Chaincase Housing retaining ring to lock position of bearing in bore Verify that. the ring is fully seated in the groove and is in proper orient. INSPECTION, 1 Inspect primary chaincase for cracks or damaged gasket. 2 Check the mainshaft bearing Replace if bearing does not. rotate freely Replace the lip seal See 6 4 PRIMARY. 2008 Softail Service Drive 6 9, NOTES MAINSHAFT BEARING INNER RACE. The lip garter spring side of the oil seal is also identified. PART NUMBER TOOL NAME, by the words OIL SIDE, HD 34902 B MAINSHAFT BEARING INNER RACE.
Install oil seal with a seal driver that will press only against REMOVER INSTALLER. outer rim of oil seal NOT against the inner area, The minimum allowable depth of the seal is reached when Removal. the outer edge of the seal carrier is flush with the machined NOTE. surface of the primary housing The maximum allowable. depth of the seal is reached when the seal carrier contacts The bearing inner race must be positioned on the shaft a pre. the mainshaft bearing snap ring cise distance to properly align with the bearing outer race in. the primary chaincase To remove and install the bearing inner. 7 Install mainshaft oil seal race use the combination MAINSHAFT BEARING INNER. a Lubricate the O D of the new seal with clean engine RACE REMOVER INSTALLER Part No HD 34902 B. oil 1 See Figure 6 24 Install washers 5 on bolts 2 Slide one. b See Figure 6 23 With the lip garter spring side bolt into channel on each side of bridge 4 so that washer. stamped oil side facing toward the bearing press is between bridge and bolt head. squarely on the outer edge of a new oil seal until outer 2 Thread bolts into stamped side of puller plate 7 an equal. edge of seal is flush with machined surface of inner number of turns. primary housing, 3 Apply graphite lubricant to threads of forcing screw 6. 8 Lubricate the bearing and seal lip with multi purpose Thread forcing screw into bridge. grease or clean engine oil, 4 Position puller plate between inner race 1 and sprocket. 5 Install end cap into end of mainshaft Thread forcing screw. into bridge until the forcing screw seats in the end cap. Continue turning forcing screw until the bearing inner race. is free of the mainshaft, 1 Retaining ring 1, 2 Oil passage. Figure 6 22 Retaining Ring Orientation, 1 Bearing inner race.
5 Washer 2, 6 Forcing screw, 7 Puller plate, Figure 6 24 Pulling Mainshaft Inner Bearing Race. Installation, 1 See Figure 6 26 Slide bearing inner race 1 chamfer. edge first onto mainshaft, Figure 6 23 Oil Seal Extension shaft has left hand threads. DRIVE COMPONENTS 6 3 REMOVAL PART NUMBER TOOL NAME HD 47977 PRIMARY DRIVE LOCKING TOOL NOTES To remove the pr imary chain remo ve compensating sproc ket clutch assembly and primary chain as an assembly 1 Remove primary chaincase cover See 6 2 PRIMARY CHAINCASE COVER Removal 2 See Figure 6 4 Remove chain tensioner fasteners 2 then remove chain tensioner 1 3 Using a colored marker

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