7.5 clutch release cover - harley-davidson-sweden.se

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HOMEf1103axx99512 11152025202418221. Side door2. Gasket3. Mainshaft spacer4. Countershaft spacer5. Mainshaft6. Countershaft7. Spacer (2)8. Locknut (2)9. Bearings, one-piecesplit cage (4)10. Mainshaft 4th gear11. Thrust washer (5)12. Retaining ring (6)13. Mainshaft 1st gear14. Countershaft 4th gear15. Retaining ring16. Countershaft 1st gear17. Countershaft 3rd gear18. Mainshaft 3rd gear19. Countershaft 2nd gear20. Thrust washer (2)21. Countershaft 5th gear22. Mainshaft 2nd gear23. Push rod24. Push rod – left side25. Clutch release bearing87162917111112 233 101112 13414161112912192112Figure 7-25. Side Door, Mainshaft and Countershaft Assembly (Exploded View)8. See Figure 7-24. Install countershaft 3rd gear with theshifter fork groove facing opposite the side door.9. Install a new retaining ring in the groove just above themainshaft 1st gear. Slide a thrust washer down themainshaft until it contacts the retaining ring. Lightly coata split caged bearing with oil and install in the mainshaftrace next to the thrust washer. Place mainshaft 3rd gearover the bearing. Install a second thrust washer and anew retaining ring above the gear10. Install a new retaining ring in the groove above the countershaft3rd gear. Slide a thrust washer down the countershaftuntil it contacts the retaining ring. Lightly coat asplit caged bearing with oil and install in the countershaftrace next to the thrust washer. Install the countershaft2nd gear over the bearing with the shifter dogs facingthe side door end of the shaft.11. Slide the countershaft 5th gear down the countershaftuntil it contacts the countershaft 2nd gear. Install a newretaining ring in the groove above the countershaft 5thgear.12. Install the mainshaft 2nd gear on the shaft with theshifter fork groove towards the side door.The final assembly appears as shown in Figure 7-24.NOTEInstall the main drive gear, if removed. See Section 7.7 MAINDRIVE GEAR, INSTALLATION.7-20 2004 Touring: Transmission
HOMEL = 5/16 InchS = 1/4 Inch5. With the transmission locked, tighten the mainshaft andcountershaft locknuts to 45-55 ft-lbs (61-75 Nm). SeeFigure 7-23.S42S6. Install the oil slinger assembly (with two-piece push rodand clutch release bearing components).7. Install shifter cam and fork assemblies. See Section 7.4SHIFTER CAM ASSEMBLY/SHIFTER FORKS,ASSEMBLY.8. Install the bearing inner race on the transmission mainshaft.See Section 6.5 PRIMARY CHAINCASE, MAIN-SHAFT BEARING INNER RACE, INSTALLATION.1LL7969Figure 7-26. Side Door Screw Size and Torque SequenceINSTALLATION5L6L39. Install the starter and oil filler spout. See Section 5.4STARTER, INSTALLATION, steps 1-3 and 5-7.10. Install the primary chaincase and starter jackshaftassembly. Install the clutch assembly, primary chain, andcompensating sprocket components. Install the primarychaincase cover. See Section 6.5 PRIMARY CHAIN-CASE, INSTALLATION.11. Install the exhaust system. See Section 3.8 INSTALL-ING ENGINE IN CHASSIS, steps 46-52.1. Verify that the two locating dowels are in place on theright side of the transmission case. Hang a new gasketon the dowels. Install the assembled side door in thetransmission case. See Figure 7-19.2. Install the four 5/16 inch screws (with flat washers) tofasten transmission exhaust bracket and bottom of sidedoor to the transmission case. Install the two 1/4 inchscrews to fasten the top of the side door to the transmissioncase. Alternately tighten six screws until snug.3. Resetting the torque wrench as necessary, tighten thefour 5/16 inch screws to 13-16 ft-lbs (18-22 Nm) and thetwo 1/4 inch screws to 84-108 in-lbs (9-12 Nm) in thesequence shown in Figure 7-26.4. Lock the transmission. This can be accomplished bymanually engaging the shifter dogs of any two gears(mainshaft or countershaft) with the shifter dogs of anadjacent gear and then turning the mainshaft locknutcounterclockwise.2004 Touring: Transmission 7-21
Page 1 and 2: HOMESPECIFICATIONS 7.1TRANSMISSION
Page 3 and 4: HOMETRANSMISSION POWER FLOW 7.2GENE
Page 5 and 6: HOMESHIFTER LINKAGE 7.3ADJUSTMENT84
Page 7 and 8: HOMEInnerRampRetainingRingCableFitt
Page 10 and 11: HOME7411b. Lubricate O-ring with cl
Page 12: HOMECLUTCH RELEASE COVER 7.5REMOVAL
Page 17: HOMEABRetaining RingCountershaft 5t
Page 22: HOMEMAIN DRIVE GEAR 7.7REMOVAL7970N
Page 25 and 26: HOME3. With the garter spring side
Page 27 and 28: HOMEd. Using the seal driver, hand
Page 29 and 30: HOME7968WasherRetainingRingSplinedS
Page 31 and 32: HOMEf1894x7x10. Install the primary

7.5 clutch release cover - harley-davidson-sweden.se

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