Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
40100061, 42200064A, 42200095A | Safety glasses, Torque wrench, Isopropyl alcohol, Loctite 262 High Strength Threadlocker, T70 TORX bit, Harley-Davidson Special Tools:
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Verify that all contents are present in the kit before installing or removing items from vehicle. | |||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
Spring Pack (includes items 1 through 3) | |||||
1 | 2 | Large disc spring | Not sold separately | ||
2 | 2 | Medium disc spring | Not sold separately | ||
3 | 1 | Small disc spring | Not sold separately | ||
* | 1 | Compensator Kit, 2006 and later Dyna, 2007 and later Touring, 2007 and later Softail (except models listed below) (includes items 4 through 13) | 36500034A | ||
* | 1 | Compensator Kit, FXCW/C (Rocker), FXSTSSE3 (Screamin' Eagle Softail Springer), FXSBSE (Screamin' Eagle Softail Breakout) and FXSB/FXSB103 (Breakout) models (includes items 4 through 13) | 36500078A | ||
4 | 1 | Shaft extension | Not sold separately | ||
5 | 1 | Sliding cam | Not sold separately | ||
6 | 1 | Compensating sprocket | Not sold separately | ||
7 | 2 | Thrust washer | 40100064 | ||
8 | 1 | Sprocket retainer | Not sold separately | ||
9 | 1 | Screw | 10500031 | ||
10 | 1 | Retainer clip | 12200065 | ||
11 | 1 | Oil deflector (Touring models) | 62700063 | ||
12 | 1 | Oil deflector (Dyna and Softail models) | 62700064 | ||
13 | 1 | Oil spinner, FXCW/C (Rocker), FXSTSSE3 (Screamin' Eagle Softail Springer), FXSBSE (Screamin' Eagle Softail Breakout) and FXSB/FXSB103 (Breakout) models only | 62700062 | ||
14 | 1 | Alternator rotor assembly (as required) | 30041-08A | ||
| 1. | Remove seat. See service manual. | |
| 2. | Disconnect battery cables (negative cable first). See service manual. |
| 1. | Remove drive components. See service manual. | |
| 2. | 2006-2011 Dyna, 2007-2011 Softail (except 2008-209 FXCW, 2008-2011 FXCWC, 2009 FXSTSSE3, 2010 FXSTSE and 2011 FXSTSE2) and 2007-2010 Touring models: Remove alternator rotor. See service manual. | |
| 3. | 2006 Dyna: Replace stator with new stator (Part No. 30017-07). See service manual. |
| 1. | See Figure 2. Assemble adhesive cartridge and Caulk Gun Conversion Kit (Part No. 11100075) into caulk gun (not included). | Figure 2. Caulk Gun and Adapter | ||||
| 2. | Clean primary cover with PJ-1 or equivalent. Wipe the deflector installation area with isopropyl alcohol to remove residue. Allow to dry completely. | |||||
| 3. | Test fit appropriate oil deflector to the cleaned primary cover: a. Touring Models: (Part No. 62700063, Item 11) b. Softail or Dyna Models: (Part No. 62700064, Item 12) | |||||
| 4. | NOTE Before applying adhesive to part, purge the epoxy from the tube until it comes out a uniform grey. a. Apply adhesive to the perimeter of the part. b. Create an "X" pattern across the part. c. Apply adhesive to the sides that contact the primary cover. | Figure 3. Apply Adhesive | ||||
| 5. | See Figure 4. Carefully position deflector in primary cover and press firmly into place. Slide deflector into position. DO NOT LIFT. | |||||
| 6. | Install retention clip over oil deflector rib and the adjacent aluminum rib as shown. | Figure 4. Install Deflector and Retaining Clip | ||||
| 7. | See Figure 5. Protect outside surface of primary cover to avoid damage. | |||||
| 8. | Secure oil deflector in place using a C-clamp. Allow approximately 30 minutes before handling. | Figure 5. Clamp Components Together | ||||
| 9. | 2006-2011 Dyna, 2007-2011 Softail (except 2008-2009 FXCW, 2008-2011 FXCWC, 2009 FXSTSSE3, 2010 FXSTSE and 2011 FXSTSE2) and 2007-2010 Touring models: See Figure 1. Install new alternator rotor (14) to engine compensating sprocket shaft. See service manual. | |||||
| 10. | See Figure 1. Apply a thin layer of primary chaincase oil to the sliding cam (5) splines and the outer splines of shaft extension (4). Install shaft extension with the flat side against alternator rotor (14). | |||||
| 11. | See Figure 6. Outer diameters of springs must contact each other as shown. | |||||
| 12. | See Figure 1. Install sliding cam (5) with flat face contacting small disc spring. Lubricate sliding cam (5) ramps with primary chaincase oil. NOTE
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| 13. | Place drive components (primary chain, compensating sprocket and clutch assembly) into position. A slight rotation of chain drive aids installation onto splines. | Figure 6. Spring Pack Sub-Assembly | ||||
| 14. | Clean and prime threads of clutch hub mainshaft nut. Apply two drops of threadlocker to threads. Start nut onto mainshaft. Hand-tighten.LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (RED) (94759-99) NOTE When installing screw (9), make sure that the disc springs are properly aligned and that the spring nearest the rotor assembly has not slipped between the extension and rotor hub. | |||||
| 15. | Lightly lubricate thrust washers (7) with a thin layer of primary chaincase oil. Install thrust washers (7), sprocket retainer (8) and screw (9). Hand tighten. | |||||
| 16. | See Figure 7. Install PRIMARY DRIVE LOCKING TOOL between teeth of engine and clutch sprocket as shown. Special Tool: PRIMARY DRIVE LOCKING TOOL (HD-48219) Special Tool: PRIMARY DRIVE LOCKING TOOL (HD-47977) |
Figure 7. Installing Engine Compensating Sprocket Bolt | ||||
| 17. | NOTE The compensating sprocket screw is a T70 Torx bit. Torque: 135.6 N·m (100 ft-lbs) NOTE Make sure shims do not fall between shaft extension and alternator rotor when loosening screw. | |||||
| 18. | Loosen screw (9) one-half turn. Angle: 180° | |||||
| 19. | Tighten screw (9). Final torque: Torque: 237.3 N·m (175 ft-lbs) | |||||
| 20. | Rocker (FXCW/C), Screamin' Eagle Softail Springer (FXSTSSE3), Screamin' Eagle Softail Breakout (FXSBSE) and Breakout (FXSB/FXSB103) models: Install oil spinner (13) on sprocket retainer (8). | |||||
| 21. | Rotate compensating sprocket (6) to make sure that there is a light pressure on sprocket from springs. a. No clearance should be felt. b. A slight rotation should be possible by hand with the transmission in neutral. | |||||
| 22. | Install remaining components. See service manual: a. Assemble remaining drive components. b. Adjust clutch. c. Install primary chain tensioner. d. Install primary chaincase cover with a new gasket (sold separately). e. Fill primary chaincase with lubricant. |
| 1. | Verify ignition/key switch is in turned OFF position. | |
| 2. | Apply a light coat of Harley-Davidson electrical contact lubricant (Part No. 99861-02), petroleum jelly or corrosion retardant material to battery terminals. | |
| 3. | Connect battery cables (positive cable first). See service manual. | |
| 4. | Install seat. Pull up on seat to verify that it is secure. See service manual. |