AUTOMATIC PRIMARY CHAIN TENSIONER
J037842011-01-13
GENERAL
Kit Number
40063-05B
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Proper installation of this kit requires the separate purchase of a primary cover gasket and other seals, that vary depending on the model. See your authorized Harley-Davidson dealer for the proper parts.
Loctite® 262 Threadlocker and Sealant (red) (94759-99) is required for proper installation on 1985-2000 model motorcycles.
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
INSTALLATION
| 1. | Refer to the appropriate Service Manual and remove seat. | |||||||||||
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) | ||||||||||||
| 2. | Disconnect negative (-) battery cable. | |||||||||||
| 3. | Refer to the appropriate Service Manual and remove primary cover. | 
Figure 1. Manual Tensioner: 1985-2000 Models | ||||||||||
| 4. | For 1985-2000 model motorcycles, remove manual tensioner and replace the carriage bolt as follows: For 2001 and later model motorcycles, remove manual tensioner as follows: a. See Figure 1. Remove two screws (5) and nut and washer (3), and remove chain tensioner (4). b. Remove two screws (1) and anchor plate (2). c. Replace the carriage bolt in the anchor plate with the carriage bolt from the kit. d. Apply 2-3 drops of Loctite 262 (red) to the threads of the anchor plate mounting screws (1), then install anchor plate and two screws. Tighten screws to 16–19 N·m (12–14 ft-lbs). e. See Figure 2. Remove nut and washer (1) and remove chain tensioner (2). | 
Figure 2. Manual Tensioner: 2001 and Later | ||||||||||
| 5. | See Figure 3. Install the autotensioner bracket (2) over the carriage bolt (1), behind the primary chain. Loosely secure the bracket using the nut and washer removed in Step 4. | |||||||||||
| 6. | See Figure 4. Install autotensioner (2) to the autotensioner bracket with two screws (3) from the kit. Do not tighten screws at this time. | |||||||||||
| 7. | See Figure 4. Position the autotensioner and bracket as follows: a. Carefully lift the autotensioner and bracket assembly to take the slack out of the chain. b. Lower the autotensioner and bracket assembly 1-2 notches to allow approximately 1 in. (25 mm) of chain freeplay at the top of the chain. c. Tighten nut (1) to 29–39 N·m (21–29 ft-lbs). d. Tighten autotensioner hex screws (3) to 23–26 N·m (17–19 ft-lbs). | |||||||||||
| 8. | Remove tie wrap and shipping plate (4) to free the autotensioner. Flex the top of the chain to allow the autotensioner to adjust itself. Once the shipping plate is removed and the chain is flexed, the spring-loaded wedge of the autotensioner should move to the left. If the shoe does not move up and down when the chain is flexed, then the autotensioner bracket is positioned too high and must be lowered. Install the shipping plate or a tie wrap to secure the shoe, loosen the nut and screws, lower the assembly, and re-tighten the nut and screws according to the specifications above. Then repeat this step. | |||||||||||
| 9. | Refer to the appropriate Service Manual and install the primary cover with a new seals and refill the primary oil. | |||||||||||
| 10. | Connect the negative (-) battery cable. | |||||||||||
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) | ||||||||||||
| 11. | Refer to the appropriate Service Manual and install the seat. |
| 1 | Carriage bolt |
| 2 | Autotensioner bracket |
Figure 3. Autotensioner Bracket
| 1 | Nut and washer |
| 2 | Autotensioner |
| 3 | Hex screw (2) |
| 4 | Shipping plate |
Figure 4. Autotensioner
Care & Maintenance
Removing the Autotensioner for Service
- Use a tie wrap and secure the shoe to the base of the autotensioner, without securing it to the autotensioner bracket. This will retain the autotensioner adjustment for reinstallation during service.
- Remove two autotensioner hex screws, and autotensioner.
Resetting the Autotensioner
- See Figure 5. Compress autotensioner wedge (1) and spring back to the base.
- Hold wedge in position by inserting a hex wrench or pick tool through the hole in the base of the autotensioner.
- See Figure 6. Move plastic autotensioner shoe (1) into place as shown.
- If available, install shipping plate (2) to secure the shoe to the base. If it is not available, secure the shoe to the base with a tie wrap.
| 1 | Autotensioner wedge |
Figure 5. Reset Autotensioner Spring and Wedge
| 1 | Autotensioner shoe |
| 2 | Shipping plate |
Figure 6. Install Shipping Plate or Tie Strap
SERVICE PARTS
Figure 7. Service Parts for Automatic Primary Chain Tensioner Kit
Table 1. Service Parts
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Carriage bolt, 3/8-16 X 1-1/4 in. (use for 1985-2000 models only) | 5416 |
2 | Screw, hex, 5/16-18 X 1-1/2 in. (2) | 2932A |
3 | Bracket, autotensioner | 40065-05 |
4 | Autotensioner | Not Sold |