Harley Davidson Touring 2004 Service Manual spb07a
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SPECIFICATIONS 7.1
Table 7-1. Transmission Data
TRANSMISSION DATA
Ty p e
SYN3
Capacity (dry)
Capacity (wet)
Quart Part No.
5-speed forward -
constant mesh
99824-03/00QT
24 oz.
710 ml
Approximately
20-24 oz.
590-710 ml
Table 7-2. Internal Gear Ratios
GEAR INTERNAL GEAR RATIOS
First 3.21
Second 2.21
Third 1.57
Fourth 1.23
Fifth 1.00
2004 FLHTCSE: Transmission 7-1
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SERVICE WEAR LIMITS 7.2
Table 7-3. Shifter Forks
SHIFTER FORKS IN. MM
Shifter fork to cam
groove end play
Shifter fork to gear
groove end play
0.0017-0.0019 0.043-0.048
0.0010-0.0110 0.025-0.279
Table 7-4. Mainshaft
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
Table 7-5. Main Drive Gear (5th)
MAIN DRIVE
GEAR (5TH)
Bearing fit in
transmission case
(loose)
Fit in bearing (tight) 0.0009 0.023
Fit in bearing (loose) 0.0001 0.0025
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
Fit on countershaft
(tight)
Fit on countershaft
(loose)
Fit on mainshaft
(tight)
Fit on mainshaft
(loose)
IN. MM
0.0003-0.0017 0.008-0.043
0.0008 0.020
0.00001 0.0003
0.0007 0.018
0.0001 0.0025
Table 7-6. Countershaft
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
Table 7-7. Shifter Dogs
SHIFTER DOG
GEARS
2nd-5th
2nd-3rd
1st-4th
1st-3rd
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
MAXIMUM
CLEARANCE
7-2 2004 FLHTCSE: Transmission
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