Harley Davidson Touring 2004 Service Manual sm07a
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SPECIFICATIONS 7.1
TRANSMISSION DATA
TRANSMISSION
Ty p e
Quart Part No. 99892-84
Semi-synthetic
transmission
lubricant
Capacity (dry)
Capacity (wet)
GEAR
First 3.21
Second 2.21
Third 1.57
Fourth 1.23
Fifth 1.00
ENGINE OIL
Capacity (dry)
Capacity (wet)
Case of Quarts Part No. 98853-96
Gallon Part No. 99891-84
Case of Gallons Part No. 98852-96
Internal Gear Ratios
(Domestic, HDI and Swiss)
DATA
5-speed forward -
constant mesh
24 oz.
710 ml
Approximately
20-24 oz.
590-710 ml
DATA
4 quarts
3.8 liters
Approximately
3-1/2 quarts
3.3 liters
SERVICE WEAR LIMITS
SHIFTER FORKS
Shifter fork to cam
groove end play
Shifter fork to gear
groove end play
SHIFTER DOG
GEARS
2nd-5th
2nd-3rd
1st-4th
1st-3rd
MAINSHAFT
TOLERANCE
Mainshaft runout 0.000-0.003 0.000-0.08
Mainshaft end play none none
1st gear clearance 0.0000-0.0080 0.000-0.203
2nd gear clearance 0.0000-0.0800 0.000-2.032
3rd gear end play 0.0050-0.0420 0.127-1.067
3rd gear clearance 0.0003-0.0019 0.008-0.048
4th gear end play 0.0050-0.0310 0.127-0.787
4th gear clearance 0.0003-0.0019 0.008-0.048
IN. MM
0.0017-0.0019 0.043-0.048
0.0010-0.0110 0.025-0.279
MINIMUM
CLEARANCE
0.035 in. 0.139 in.
0.89 mm 3.53 mm
0.035 in. 0.164 in.
0.89 mm 4.17 mm
0.035 in. 0.152 in.
0.89 mm 3.86 mm
0.035 in. 0.157 in.
0.89 mm 3.99 mm
IN. MM
MAXIMUM
CLEARANCE
CAUTION
A bent jiffy stand, modified suspension or uneven parking area can cause dipstick to indicate a false low oil
condition.
NOTE
Since a sidecar equipped motorcycle is fixed in an upright
position, the actual full engine oil level is about 1/2 inch (12.7
mm) above the FULL mark on the dipstick.
MAIN DRIVE
GEAR (5TH)
Bearing fit in
transmission case
(loose)
Fit on mainshaft 0.0001-0.0009 0.0025-0.023
End play none none
Fit in side door (tight) 0.0014-0.0001 0.036-0.0025
2004 Touring: Transmission 7-1
IN. MM
0.0003-0.0017 0.008-0.043
HOME
SERVICE WEAR LIMITS (CONT.’D)
COUNTERSHAFT
TOLERANCE
Countershaft runout 0.000-0.003 0.00-0.08
Countershaft end play none none
1st gear clearance 0.0003-0.0019 0.008-0.048
1st gear end play 0.0050-0.0039 0.127-0.099
2nd gear clearance 0.0003-0.0019 0.008-0.048
2nd gear end play 0.0050-0.0440 0.127-1.118
3rd gear clearance 0.0000-0.0080 0.000-0.203
4th gear clearance 0.0000-0.0080 0.000-0.203
4th gear end play 0.0050-0.0390 0.127-0.991
5th gear clearance 0.0000-0.0080 0.000-0.203
5th gear end play 0.0050-0.0040 0.127-0.102
IN. MM
TORQUE VALUES
Item
Shifter linkage rod
locknuts
Detent arm pivot screw
to right support block
Shifter cam support
block screws
Tr an smission top cover
socket head screws
Neutral switch
Clutch release cover
socket head screws
Clutch cable fitting 36-60
Tr an smission lubricant
drain plug
Tr ansmission filler
plug/dipstick
Tr an smission side door
5/16 inch screws
1/4 inch screws
Mainshaft/countershaft
locknuts
Tr an smission mainshaft
sprocket nut
Tr ansmission sprocket
nut lockplate screws
Oil pan bolts 84-108
Tr ansmission-to-engine
mounting bolts
Oil hose cover 84-108
Rear swingarm
bracket bolts
Rear swingarm
pivot shaft locknut
Shifter lever to shifter
shaft socket head screw
Engine oil drain plug 14-21 ft-lbs 19-28 Nm
ft/in-lbs Nm
80-120
in-lbs
84-108
in-lbs
84-108
in-lbs
84-108
in-lbs
120-180
120-144
in-lbs
in-lbs
in-lbs
14-21 ft-lbs 19-28 Nm
25-75
in-lbs
13-16 ft-lbs
84-108
in-lbs
45-55 ft-lbs 61-75 Nm
60 ft-lbs, then
35° to 45°
90-110
in-lbs
in-lbs
15 ft-lbs,
then
30-35 ft-lbs
in-lbs
34-42 ft-lbs 46-57 Nm
40-45 ft-lbs 54-61 Nm
18-22 ft-lbs 24-30 Nm
9.0-13.6 Nm
9.5-12.2 Nm
9-12 Nm
9-12 Nm
13.6-20.3 Nm
13.6-16.3 Nm
4-7 Nm
2.8-8.5 Nm
18-22 Nm
9-12 Nm
81 Nm, then
35° to 45°
10.2-12.4 Nm
9-12 Nm
20.3 Nm,
40.7-47.5 Nm
10-12 Nm
then
7-2 2004 Touring: Transmission
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TRANSMISSION POWER FLOW 7.2
GENERAL
See Figure 7-1. The 5-speed transmission consists of two
parallel shafts supporting five gears each. The longer, or
mainshaft, also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft.
Each gear on the mainshaft is in constant mesh with a corresponding gear on the countershaft. Each of these five pairs
of gears makes up a different speed in the transmission.
The transmission gears are divided into two types, gears that
are splined and rotate with the shaft, and freewheeling gears
that ride on bearings and spin freely on the shaft. A splined
gear always meshes with a freewheeling gear. Also, three of
the splined gears are able to slide sideways on the shaft.
These sliding gears are used to change transmission
speeds. The projections (or dogs) on the sides of the sliding
gears, engage dogs on adjacent freewheeling gears, transmitting power through the transmission.
Gear shifting is accomplished by three forks which fit into
grooves machined into the hubs of the three sliding gears.
The position of the shifter forks is controlled by a drumshaped shifter cam located on the top of the transmission.
Neutral
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft 1st and 2nd
gears are rotating, but no power is transferred to the countershaft since countershaft 1st and 2nd are freewheeling gears.
4th Gear
The shift into fourth is made when mainshaft 2nd is disengaged from mainshaft 3rd and mainshaft 1st engages mainshaft 4th, locking it to the mainshaft.
5th Gear
The shift from fourth to fifth gear occurs when mainshaft 1st
is shifted out of mainshaft 4th, and mainshaft 2nd is shifted
directly into the main drive gear. Mainshaft 2nd lock the main
drive gear to the mainshaft resulting in a direct one-to-one
drive ratio from the clutch to the sprocket.
1st Gear
When the transmission is shifted into first gear, countershaft
3rd, which rotates with the countershaft, engages countershaft 1st, which has been spinning freely on the countershaft
driven by mainshaft 1st.
Now countershaft 3rd is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft
5th to turn. Countershaft 5th transmits the power to the main
drive gear and the sprocket.
2nd Gear
Second gear is engaged when countershaft 3rd is shifted out
of countershaft 1st and engages countershaft 2nd. This locks
countershaft 2nd to the countershaft to complete the power
flow as shown.
3rd Gear
Tw o shifter forks are used to make the shift from second to
third. One fork moves countershaft 3rd out of countershaft
2nd to its neutral position, while another fork engages mainshaft 2nd with mainshaft 3rd. This locks mainshaft 3rd to the
mainshaft to complete the power flow as shown.
2004 Touring: Transmission 7-3
HOME
Neutral 1st Gear
4
Countershaft
Mainshaft
In
2
5
Out
2
5
1
3
3rd Gear 2nd Gear
In
52
Out
3
1
4
5
In
2
1
3
3
4
1
4
5th Gear 4th Gear
In
52
3
Sliding Member Power Flow
7-4 2004 Touring: Transmission
Out
1
4
Figure 7-1. Transmission Power Flow Schematic
Out
52
In
3
1
4
HOME
8471
Locknut
Locknut
Rod
SHIFTER LINKAGE 7.3
ADJUSTMENT
If operating problems exist, check the shifter linkage for wear,
interference or adjustment. If adjustment is necessary, see
SHIFTER LINKAGE below. If problems persist, see the
checks under Section 1.1 TROUBLESHOOTING, TRANS-
MISSION, along with the repair procedures in this section.
Shifter Linkage
The shifter linkage is set at the factory and should not need
adjustment under normal circumstances. However, if full
engagement or full lever travel is not achieved, adjust the
linkage rod as follows:
CAUTION
To ensure proper gear engagement and avoid possible
damage to transmission, the shifter lever should not
contact the footboard when shifting. A minimum clearance of 3/8 inch (9.5 mm) between shifter lever and footboard must be maintained to accommodate engine
movement when running.
1. Remove locknut, lockwasher and flat washer to free front
end of shifter rod from shifter lever. See Figure 7-2.
2. Loosen locknuts and adjust rod as necessary.
3. Install flat washer, lockwasher and locknut to fasten front
4. Tighten locknuts to 80-120
Figure 7-2. Shifter Linkage Adjustment
end of shifter rod to shifter lever.
in-lbs
(9.0-13.6 Nm).
2004 Touring: Transmission 7-5
HOME
SHIFTER CAM ASSEMBLY/SHIFTER FORKS 7.4
DISASSEMBLY
1. Remove maxi-fuse. See Section 8.3 SYSTEM FUSES,
MAXI-FUSE, REMOVAL.
2. Remove the exhaust system in two sections. See Section 3.7 REMOVING ENGINE FROM CHASSIS, steps 3-
9.
3. Remove the magnetic drain plug at the bottom right side
of the oil pan and drain the transmission lubricant into a
suitable container. Remove the fill plug/dipstick.
4. Using fingers and flat tip screwdriver, remove two elbow
connectors from neutral switch studs. Using 7/8 inch box
end wrench, remove neutral switch and O-ring from
transmission top cover. Remove preformed vent hose
from the top cover fitting, if necessary.
5. Remove the five socket head screws from the transmission top cover. Remove the top cover from the transmission case. Remove and discard the cover gasket.
f1889b7x
CAUTION
Pulling shifter cam assembly from dowels allows left
support block to rotate freely, which can cause screws
and washers to drop into transmission case if left
loosely installed.
6. See Figure 7-3. Remove the four hex head screws (with
flat washers) to free the right and left shifter cam support
blocks. Raise shifter pawl and lift shifter cam assembly
from dowels on deck of transmission case.
7. See CLEANING AND INSPECTION, steps 2 and 3, on
the next page. If necessary, disassemble shifter cam
assembly as follows:
1WARNING1WARNING
Always wear proper eye protection when removing retaining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
Flat
Washer
Hex Head
Screw
Retaining
Ring
Retaining
Ring
Washer
Roller
Bearing
Hex Head
Screw
Flat
Shifter Cam
Right
Support Block
Figure 7-3. Shifter Cam Assembly
Detent
Arm
Spiral
Lock Ring
Roller
Bearing
Left
Support Block
Spring
Pivot
Screw
Spring
Sleeve
7-6 2004 Touring: Transmission
HOME
1WARNING1WARNING
f1892x7x
Fork
Shaft
Inner
Ramp
Retaining
Ring
Cable
Fitting
12. Remove the fork shaft from the hole on the right side of
the transmission case. See Figure 7-5. Remove the
shifter forks from the mainshaft and countershaft gear
grooves.
13. To replace the transmission gears or side door bearings,
see Section 7.6 MAINSHAFT/COUNTERSHAFT. To
replace the main drive gear, see Section 7.7 MAIN
DRIVE GEAR.
CLEANING AND INSPECTION
f1896x7x
a. Retract detent arm and slide right support block off
b. Moving to opposite side, remove spiral lock ring
c. Slide left support block off end of shifter cam.
8. Slide rubber boot off clutch cable adjuster. Holding cable
adjuster with 1/2 inch wrench, loosen jam nut using 9/16
inch wrench. Back jam nut away from cable adjuster.
Move adjuster toward jam nut to introduce a large
amount of free play at hand lever.
Coupling
Figure 7-4. Clutch Release Cover Assembly
end of shifter cam. Remove pivot screw to release
detent arm, spring sleeve and spring. Remove and
discard retaining ring. Press against inner race of
roller bearing to remove from support block. Discard
roller bearing.
from groove at left end of shifter cam. Using a small
knife, push on end of spiral lock ring working tip of
blade under edge of ring. Raise end of ring until free
of ring groove. Work around circumference of ring to
alternately pull spirals from ring groove. Discard
ring.
Remove and discard retaining ring. Press against
inner race of roller bearing to remove from support
block. Discard roller bearing.
Clutch Cable
Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
in death or serious injury.
1. Clean all parts with solvent (except left and right support
blocks if roller bearings installed). Blow dry with low
pressure compressed air.
2. Inspect roller bearings. Verify that bearings rotate freely
without sticking.
3. Inspect the shifter cam for cracks or wear. Inspect the
ends for grooves or pitting. Install
whenever the shifter cam is replaced.
4. Check the shifter fork shaft. Replace if bent or damaged.
5. Using a small carpenter’s square, verify that the shifter
fork shafts are square. If a fork does not rest directly on
the square, then it is bent and must be replaced. See
Figure 7-6.
new
roller bearings
9. Remove six socket head screws to free clutch release
cover from transmission side door. Remove and discard
gasket.
10. Remove retaining ring and lift inner ramp out of clutch
release cover. Turn the inner ramp over so that ball sockets are facing outboard. Remove hook of ramp from button on coupling. Remove coupling from clutch cable end.
See Figure 7-4.
11. Unscrew the cable fitting from the clutch release cover.
Remove clutch cable and fitting.
Figure 7-5. Remove Fork Shaft/Shifter Forks
(Right Side View)
2004 Touring: Transmission 7-7
HOME
f1888x7x
Carpenter’s
Square
Shifter
Fork
Fork Shaft
Figure 7-6. Check Shifter Forks for Squareness
ASSEMBLY
1. See upper frame of Figure 7-8. Find the shifter fork with
the centered pin. Holding the fork so that the pin is positioned at the rear of the transmission case, install the
fork in the countershaft gear fork groove. See Figure 7-9.
2. Slide the two outer forks into the mainshaft gear fork
grooves so that the pins are positioned on the inside (offset outboard). After installation, the pins of all three forks
should be in alignment.
SHIFTER FORKS
Centered
Shifter
Shaft
Offset
Outboard
Pin
Mainshaft
7976
1
2
3
Right
Side
Left
Side
0.165 in. (4.19 mm)
Minimum
(2 places on each fork)
1. 4th gear shifter fork
2. 1st and 2nd gear shifter fork
3. 3rd and 5th gear shifter fork
f1100bxx
Figure 7-7. Shifter Fork Identification
6. Inspect the shifter forks for wear. With a micrometer or
dial caliper, measure the width of the forks where they
contact the gear fork grooves. Replace any fork that
measures less than 0.165 inch (4.19 mm). See Figure 7-
7.
7. Inspect the neutral switch. Depress plunger and observe
the action. Plunger should spring back without binding.
Switch is non-repairable and must be replaced if defective. See ASSEMBLY, step 11.
Countershaft
SHIFTER CAM ASSEMBLY
Right
Detent
Arm
Support Block
Shifter
Cam
Left
Support Block
Shifter
Pawl
Figure 7-8. Install Shifter Forks/Shifter Cam
7975
7-8 2004 Touring: Transmission
HOME
7410
7411
Left Side
Right Side
Roller
Bearing
Spiral
Lock Ring
Retaining Ring
Beveled Side Out
Left
Support Block
Roller
Bearing
Retaining Ring
Beveled Side Out
Right
Support Block
8256
Countershaft
Mainshaft
Fork Groove
Fork Groove
Fork Groove
Figure 7-9. Shifter Fork Groove Locations
3. Insert the fork shaft into the hole on the right side of the
transmission case. Slide the shaft through the shifter
forks and into the drilling on the left side of the case. See
Figure 7-5.
c. Place right support block under ram of arbor press.
Center
new
roller bearing over bore with the lettered side up. Using a suitable driver, press against
outer race until bearing makes firm contact with the
counterbore. Install
new
retaining ring with the flat
side in against the bearing (beveled side out). See
lower frame of Figure 7-10.
d. Hold spring so that ends are pointing to the right.
Insert long end of spring sleeve into right side of
spring. Insert pivot screw into left side of spring
sleeve. With roller facing screw head, slide detent
arm onto short end of spring sleeve positioning arm
between spring ends. Start pivot screw into
threaded hole in right support block positioning support block between spring ends. Tighten pivot screw
to 84-108
in-lbs
(9.5-12.2 Nm). Retract detent arm
and slide right support block onto end of shifter
cam. See Figure 7-11.
4. Check the sliding movement of the forks and gears. All
parts should move freely without binding.
1WARNING1WARNING
Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage may propel the ring with enough force to
cause eye injury.
5. If disassembled, assemble shifter cam assembly as follows:
a. Place left support block under ram of arbor press.
Center
tered side up. Using a suitable driver, press against
outer race until bearing makes firm contact with the
counterbore. Install
new
roller bearing over bore with the let-
new
retaining ring with the flat
side in against the bearing (beveled side out). See
upper frame of Figure 7-10.
b. Place left support block onto end of shifter cam.
Start bottom end of
new
spiral lock ring into ring
groove. Alternately work around circumference of
ring feeding each spiral into the ring groove a section at a time. When complete, verify that spiral lock
ring is fully seated in the groove.
Figure 7-10. Shifter Cam Assembly
2004 Touring: Transmission 7-9
HOME
7411
Pivot
Screw
Detent
Arm
Spring
Spring Sleeve
Figure 7-11. Shifter Cam Assembly
6. To ensure proper location, verify that four locating dowels are in place on the deck of the transmission case.
7. Raise the shifter cam pawl and place the shifter cam
assembly over the locating dowels. See Figure 7-12.
While aligning the holes in the support blocks with the
dowels on the deck of the transmission case, slide the
shifter forks as necessary so that the fork pins engage
the channels in the shifter cam. See lower frame of Fig-
ure 7-8.
8. Hand start the hex head screws (with flat washers) to
fasten the right and left support blocks to the transmission case. Alternately tighten the four support block
screws to 84-108
in-lbs
(9-12 Nm) in a crosswise pat-
tern.
NOTE
Check the gear engagement and clearance in every gear to
make sure assembly and alignment is correct.
9. Obtain a
new
top cover gasket and align the holes with
those in the transmission case. Align the holes in the top
cover with those in the gasket. Install the five socket
head screws and tighten to 84-108
in-lbs
(9-12 Nm).
The long screw is installed in the center hole on the left
side of the top cover.
10. Install preformed vent hose to top cover fitting, if removed.
b. Lubricate O-ring with clean transmission oil.
c. Using 7/8 inch box end wrench, install neutral
switch with O-ring in the transmission top cover.
Tighten to 120-180
in-lbs
(13.6-20.3 Nm).
d. Install the two elbow connectors on neutral switch
studs.
NOTE
The neutral switch is not polarity sensitive, so the elbow connectors can be attached to either stud.
12. See Figure 7-4. Install clutch cable fitting into clutch
release cover. Do not tighten at this time.
NOTE
Replace cable fitting O-ring if damaged or deformed.
13. Hold clutch cable coupling with button facing outboard.
Place cable end in recess of coupling. With ball sockets
facing outboard, place hook of inner ramp on button of
coupling. Holding inner ramp and coupling together, turn
the assembly over. Place inner ramp (ball socket side
down) over balls in outer ramp sockets. Install the retaining ring so that the opening is above and to the right of
the outer ramp tang slot in the clutch release cover.
14. Verify that the two locating dowels are in place on the
transmission side door. Hang a
new
gasket on the dow-
els.
15. Holding clutch release cover in position against transmission side door, install six socket head screws. Alternately tighten screws to 120-144
in-lbs
(13.6-16.3 Nm)
in the sequence shown in Figure 7-13.
16. Tighten clutch cable fitting to 36-60
f1891x7x
in-lbs
(4-7 Nm).
Locating
Dowels
NOTE
Whenever the transmission top cover is removed, be sure to
install neutral switch after top cover installation to ensure
proper switch engagement.
11. Install the neutral switch in the transmission top cover as
follows:
a. Roll the vehicle back and forth to verify that the
transmission is in NEUTRAL.
7-10 2004 Touring: Transmission
Figure 7-12. Place Support Blocks on Locating Dowels
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