torque specs for shovelhead primary

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  torque specs for shovelhead primary Direct Download speed 5282 Kb/s

  torque specs for shovelhead primary Full Version speed 6162 Kb/s



2008 FLT Police Models Service Manual Supplement

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Filed Under (Harley Davidson) by admin on 25-11-2010

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ITEM SERVICED 14-21 ft-lbs (19.0-28.5 Nm) Drain plug torque Engine oil and filter 4 qt. (3.8 L) Oil capacity Hand tighten 1/2-3/4 turn after gasket contact Filter 63798-99A Chrome filter part number 63731-99A Black filter part number FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity Primary chain lubricant Wet: 38 oz. (1124 ml) Dry: 45 oz. (1331 ml) 14-21 ft-lbs (19.0-28.5 Nm) Primary chaincase drain plug torque 1/2-1 turn Adjuster screw free play Clutch adjustment 72-120 in-lbs (8.1-13.6 Nm) Adjuster screw locknut torque 1/16-1/8 in. (1.6-3.2 mm) Free play at hand lever 84-108 in-lbs (9.5-12.2 Nm) Clutch inspection cover torque Dipstick at FULL with motorcycle on jiffy stand and filler plug resting on threads. Lubricant level Transmission lubricant FORMULA+ TRANSMISSION AND PRIMARY CHAIN LUBRICATION (Part No. 99851-05) Lubricant type and capacity 32 oz (0.95 liters) 14-21 ft-lbs (19.0-28.5 Nm) Transmission drain plug torque 25-75 in-lbs (2.8-8.5 Nm) Transmission filler plug/dipstick torque Front: 36 psi (248 kPA) Pressure: solo rider Tire pressure and wear Rear: 36-40 psi (248-276 kPA) Replace if less than 1/32 in. (0.8 mm) of tread pattern Wear 55 in-lbs (6.2 Nm) minimum Spoke nipple torque Wheel spokes 99953-99A (12 oz.) D.O.T. 4 hydraulic brake fluid part number Brake fluid level Front: 0.20 in. (5.0 mm) Fluid level (from top of master cylinder reservoir) Rear: 0.26 in. (6.5 mm) Front: 7-10 in-lbs (0.8-1.1 Nm) Master cylinder reservoir cover screw torque Rear: 12-15 in-lbs (1.4-1.7 Nm) 0.016 in. (0.4 mm) Minimum brake pad thickness Brake pads and discs 75-102 in-lbs (8.5.-11.5 Nm) Brake caliper pad pin torque Front: 0.18 in. (4.5 mm) Minimum brake disc thickness Rear: 0.25 in. (6.3 mm) 0.008 in. (0.2 mm) Maximum brake disc lateral runout (warpage) 10 lb. (4.5 kg) Upward force applied at midpoint of bottom belt strand Drive belt deflection 3/8-7/16 in. (9.5-11.1 mm) FLHTP 1/4-5/16 in. (6.4-7.9 mm) FLHP/FLHPE 40-60 in-lbs (4.5-6.8 Nm) Air cleaner cover bracket screw torque Air cleaner 36-60 in-lbs (4.1-6.8 Nm) Air cleaner cover screw torque LOCTITE MEDIUM STRENGTH THREADLOCKER 243 (BLUE) Air cleaner cover screw Threadlocker Part No. 99642-97 (6 ml) LUBIT-8 SUPER OIL, Part No. 94968-85TV (1/4 fl. oz.) Lubricant part number Clutch cable 35-45 in-lbs (4.0-5.1 Nm) Handlebar switch housing screw torque

HARLEY DAVIDSON CHROME INNER PRIMARY HOUSING INSTALLATION INSTRUCTION

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Filed Under (Harley Davidson) by admin on 29-01-2011

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Kit Contents Table 1. Kit Contents Part Number Description (Quantity) Not sold separately Chrome Inner Primary Housing 786A Sealing fastener (5) INSTALLATION NOTES Whenever the sealing fasteners are loosened or removed, they must be replaced. Always replace using Harley-Davidson® Original Equipment sealing fasteners part 786A. Do not use part 786. The primary housing included in this kit installs in the same manner as the stock inner primary housing with the following exception: Use the five sealing fasteners included with this kit. Install and tighten fasteners to the torque specified below. For 2006 Dyna model motorcycles: Remove dowel pins from the chrome inner primary housing before attempting installation. Using a pair of pliers or vice grips, remove the dowel pins by carefully twisting and pulling on the pins. Be careful not to scratch or mar the chrome or sealing surfaces of the chrome inner primary housing. Remove the chain tensioner anchor plate, bolt and screws from the stock inner primary housing after it has been removed, then install it on the chrome inner primary housing. See the appropriate Service Manual for the proper tightening procedure, and torque specifications. 1. See the Drive section of the appropriate Service Manual, and remove the stock inner primary housing. Clean the internal threads in the crankcase and transmission case where the sealing fasteners were removed using a wire brush. Install the chrome inner primary housing as indicated below. Replace the five stock sealing fasteners with the five bolts included in this kit. Put a light coat of primary oil under the head of the sealing fasteners and then tighten to 23-25 ft- lbs (31-34 Nm)

Harley-Davidson Softail Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 02-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the fasteners that secure the seat. Remove seat. 6. Disconnect negative Battery Terminal. 7. Remove the Saddle Bags. And their hardware. If equipped. 8. Loosen Muffler Clamp on both Mufflers and other attaching hardware. Remove and discard both Mufflers. 9. Loosen the 4 exhaust stud nuts and save. Remove and discard head pipes and exhaust gaskets. 10. Disconnect the Rear Lamp Wiring Harness. 11. Remove any fasteners from Electrical Box. 12. Remove and discard Rear Fender, Fender Support and fasteners. NOTE: 2008-Current various models. Remove ECM from Fender and save nuts. 13. Drain all Brake Fluid from the Rear Brake System. 14. Un-clamp Rear Brake Line from the frame and Rear Fork. 15. Remove and discard both Banjo Bolts and Crush Washers from the Rear Brake Caliper and the Rear Brake Master Cylinder. 16. Remove Brake Light Switch from the Brake line, Save for reassembly. 17. Remove the Torx screw from the Brake Line bracket, Save the Torx screw for reassembly. 18. Remove and Discard Brake Line. 19. If Lower Controls option. Remove and Discard right and left floorboards/foot pegs, brake pedal, shifter, and shift linkage. Remove and Discard Passenger Foot pegs or Floorboards and their mounts. Then skip to step 24. 20. If Lower Controls Not purchased. Continue. 21. Remove acorn nut from Shift Linkage. 22. Remove 3 fasteners from Drivers Floorboard and remove. 23. Remove and discard Jiffy Stand. 24. Remove the Primary Cover by first removing the top and rear inspection cover screws. 25. Continue by removing remaining fasteners. 14 total. 26. Remove and discard Primary Cover Gasket. 27. Clean residual gasket material from both surfaces. 28. Loosen the Top Center Nut on the Primary Chain Adjuster. Lower the Primary Chain Adjuster until it rests flat on the Inner Primary Cover. 29. Remove the Clutch Lifter Retaining Ring from the Clutch Basket. Remove Clutch Lifter Assembly. 30. Using the Primary Drive Locking Tool. Loosen the Compensating Sprocket Nut. 31. Using the Primary Drive Locking Tool. Loosen the Clutch Hub Main shaft Nut. WARNING: This nut is LEFT HAND threaded. 32. Remove the Primary Drive Locking Tool, Compensating Sprocket Nut, and Clutch Hub Main shaft Nut. 33. Remove the Sprocket cover and Sliding Cam from the Crank Shaft Extension. 34. Remove the Clutch Assembly, Primary Chain, Compensating Sprocket, and Crank Shaft Extension in one assembly.

HARLEY DAVIDSON CHROME INNER PRIMARY COVERS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 23-02-2011

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INSTALLATION 1 2 3 is06139 Figure 1. Remove Three Original Equipment Screws As Shown 1. See Figure 1. Remove the stock fasteners as shown in Figure 1. Save screw (3) for reuse. 2. Install the stock fastener in the rear inner cover. Place a locating washer over the fastener with the rounded side facing toward the hole in the primary chain case. 3. Slide the rear inner cover into place and loosely secure it with the stock fastener. 1 is06416 1. Acorn nut Figure 2. Fasten Front And Rear Inner Primary Covers Together 4. See Figure 2. Position the front inner cover over the rear inner cover and make sure that the hole in the front cover fits over the threaded stud in the rear cover. Secure the covers together with the acorn nut installed finger tight. 5. See Figure 3 and Table 1. Place the new 4.25 inch (5) and 1-1/2 inch (4) screws in the front inner primary cover. Place locating washers (6) over the fasteners with the rounded side of the washer facing toward the hole in the primary chain case. 6. Tighten all three screws to 108-120 in-lbs (12.2-13.6 Nm) . 7. Tighten the acorn nut. 8. Push the Allen hole plugs (7) into the four exposed screw heads

HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

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