The chaincase lubricant level should be checked monthly.
Refer to Maintenance Scheduling → Regular Service Intervals → Regular Service Intervals: 2005 Dyna Models. The chaincase lubricant should be drained and refilled with fresh lubricant at proper intervals.
NOTE
When checking the chaincase lubricant level, motorcycle should be standing STRAIGHT UP, not leaning on the jiffy stand. Keep motorcycle upright for a short period of time to equalize lubricant level in the chaincase compartments.
Check Lubricant Level
1. Ride motorcycle until engine is warmed up to normal operating temperature.
2. When motorcycle reaches normal operating temperature, turn engine off and position motorcycle STRAIGHT UP and LEVEL.
3. See Figure 1. Using a T27 TORX drive head, remove five screws (3) (with captive washers) to free clutch inspection cover (2) from primary chaincase cover.
NOTICE
Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)
4. See Figure 2. With vehicle standing upright, not leaning on the jiffy stand, the lubricant level must be visible in the bottom of the chaincase and must not be any higher than the bottom of the diaphragm spring.
NOTE
Use only Harley-Davidson PRIMARY CHAINCASE LUBRICANT (Part No. 99887-84 quart or 99886-84 gallon).
5. Refer to procedure in Changing Chaincase Lubricant to install gasket and clutch inspection cover.
1Gasket
2Clutch inspection cover
3Screws with captive washer
Figure 1. Clutch Cover
Figure 2. Lubricant Level with Motorcycle Upright
Changing Chaincase Lubricant
1. Ride motorcycle until engine is warmed up to normal operating temperature.
NOTICE
When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)
2. See Figure 1. Using a T27 TORX drive head, remove five screws (3) (with captive washers) to free clutch inspection cover (2) from primary chaincase cover.
3. See Figure 3. Remove magnetic drain plug at bottom of primary chaincase cover. Drain lubricant into suitable container.
NOTE
Dispose of chaincase lubricant in accordance with local regulations.
4. Clean drain plug. If plug has accumulated a lot of debris, inspect the condition of the chaincase components.
5. Inspect drain plug o-ring for cuts, tears or signs of deterioration. Replace as necessary.
6. Install drain plug back into primary chaincase cover. Tighten plug to 4.1–6.8 N·m (36–60 in-lbs).
NOTICE
Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)
7. Pour 26 ounces (0.77 liter) of Harley-Davidson PRIMARY CHAINCASE LUBRICANT (Part No. 99887-84 quart or 99886-84 gallon) through the clutch inspection cover opening.
NOTE
Use only Harley-Davidson PRIMARY CHAINCASE LUBRICANT (Part No. 99887-84 quart or 99886-84 gallon).
WARNING
Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)
NOTICE
When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)
8. To avoid punching holes in the clutch inspection cover gasket or enlarging existing holes, install clutch inspection cover and new gasket as follows:
a. Align the triangular shaped hole in the gasket with the top hole in the clutch inspection cover. Be sure the rubber molding and the words "towards clutch" face the motorcycle.
b. Insert screw (with captive washer) through clutch inspection cover and carefully thread it all the way through triangular shaped hole in gasket. Do not push screw through hole.
c. Hang the clutch inspection cover on the primary chaincase cover flange by starting the top cover screw.
d. Start the remaining four screws (with captive washers).
e. Using a T27 TORX drive head, alternately tighten screws to 9.5–12.2 N·m (84–108 in-lbs) in the pattern shown in Maintenance and Lubrication → Primary Chain Adjustment → Primary Chaincase Cover.
14.1-6.8 N·m (36-60 in-lbs)
Figure 3. Removal/Installation of Chaincase Drain Plug