REMOVAL
1. Remove maxi-fuse. See 8.5 SYSTEM FUSES AND RELAYS.
2. Remove right side exhaust system. See 4.18 EXHAUST SYSTEM.
3. 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 free play at hand lever. See Figure 2-84.
4. Remove retaining ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin. See Figure 2-85.
5. Remove clutch hand lever from clutch lever bracket. If necessary, remove two T27 TORX screws (with flat washers) to release handlebar clamp from clutch lever bracket.
6. Remove anchor pin and clutch cable eyelet from clutch hand lever.
7. 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 filler plug/dipstick.
8. Remove six socket head screws (with captive washers) to free clutch release cover from two dowel pins on trans-mission side door flange. Remove and discard gasket.
4
3
2 1
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1. Rubber boot 2. Cable adjuster 3. Jam nut 4. Cable end
Figure 2-84. Clutch Cable Adjuster
1
1. Retaining ring 2. Pivot pin
3. Clutch lever bracket 4. Hand lever
5. Bushing
6. Anti-rattle spring and screw 7. Screw
8. Flat washer 9. Handlebar clamp 10. Anchor pin 11. Clutch cable 12. O-ring
Figure 2-85. Clutch Hand Lever Assembly
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
9. Remove retaining ring securing ball and ramp mechanism to clutch release cover. See Figure 2-86.
10. Lift inner ramp out of clutch release cover and turn the assembly over so that ball sockets are facing outboard.
Remove hook of ramp from button on coupling. Remove clutch cable barrel from recess in coupling.
11. Remove balls from outer ramp sockets. Remove outer ramp from clutch release cover.
12. Unscrew the clutch cable fitting from the clutch release cover. Remove clutch release cover from motorcycle.
13. Cut cable strap in hole of crossbrace to free clutch cable from right frame downtube. See Figure 2-87. Continue as follows:
a. FLHR/C: Remove acorn nut to release P-clamp from stud in upper fork bracket. Remove clutch cable from P-clamp. See Figure 2-88.
b. FLHX, FLHT/C/U: Remove outer fairing. See 2.35 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U. Cut cable strap to release clutch cable from left fairing bracket. See Figure 2-89.
c. FLTR: Release clutch cable from cable clip anchored in hole on left side of instrument nacelle.
14. Remove clutch cable from motorcycle.
1
2 6
3 4
5
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1. Clutch release cover 2. Retaining ring 3. Outer ramp 4. Ball and socket 5. Inner ramp 6. Coupling
Figure 2-86. Disassemble Clutch Release Cover
INSTALLATION
1. See Figure 2-85. Insert clutch cable eyelet into groove of clutch hand lever aligning eyelet with hole without bushing.
Insert anchor pin through lever and eyelet.
2. Insert lever into groove of clutch lever bracket fitting sleeve at end of cable housing into bore on inboard side of bracket.
3. Align hole in hand lever with hole in bracket and install pivot pin. Install retaining ring in pivot pin groove.
4. If removed, install two T27 TORX screws (with flat
5. Start clutch cable routing as follows:
a. FLHR/C: Capture clutch cable in clamp. Slide P-clamp on stud in upper fork bracket and install acorn nut. Orient P-clamp as shown in Figure 2-88. On left side of steering head, run cable downward between engine guard and front of left frame downtube.
b. FLHX, FLHT/C/U: Feed clutch cable through grommet on left side of inner fairing. Route cable on inboard side of left fairing bracket between upper and lower wings of radio (or storage box) support bracket. Cable strap clutch cable to left fairing bracket using oblong hole at this location. See Figure 2-89. Run the cable downward along left side of steering head, and then between engine guard and front of left frame down-tube. Install the outer fairing. See 2.35 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U.
c. FLTR: Capture clutch cable in cable clip and anchor clip in hole on left side of instrument nacelle. Run cable forward and then rearward beneath instrument nacelle following left side of steering head. Run cable downward between engine guard and front of left frame downtube.
1 2
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1. Cable strap
2. Right frame downtube
Figure 2-87. Clutch Cable Routing (Right Side View)
1 2
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1. P-clamp 2. Acorn nut
Figure 2-88. FLHR/C Clutch Cable Routing (Left Side View)
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Figure 2-89. Secure Clutch Cable to Fairing Bracket
6. All Models, Continue downward progression while crossing to right side of motorcycle and then run cable between outboard side of voltage regulator and inboard side of right frame downtube. Threading cable strap through hole in crossbrace, secure clutch cable to down-tube as shown in Figure 2-87. Following inboard side of frame downtube, route cable between bottom of cam cover and top of lower frame tube to area of clutch release cover.
7. Inspect cable fitting O-ring and replace if damaged or deformed. Install clutch cable fitting into clutch release cover. Do not tighten cable fitting at this time.
8. Place outer ramp (ball socket side up) in clutch release cover with tab in cover slot. See Figure 2-90.
9. Apply a multi-purpose grease to the balls and outer ramp sockets. Place a ball in each of three outer ramp sockets.
10. Hold coupling with button facing outboard. Install clutch cable barrel in recess of coupling. With ball sockets facing
Holding inner ramp and coupling together, turn the assembly over.
11. Place inner ramp (ball socket side down) over balls in outer ramp sockets.
Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a)
12. Install retaining ring, so that the gap is centered above the break in the ribbing at bottom of clutch release cover. See Figure 2-90.
13. Verify that two dowel pins are in place on transmission side door flange. Hang a new gasket on the dowel pins.
14. Holding the clutch release cover in position, install six socket head screws (with captive washers).Tighten screws to 84-108 in-lbs (9.5-12.2 Nm) in the sequence shown in Figure 2-91.
15. Tighten clutch cable fitting to 90-120 in-lbs (10.2-13.6 Nm).
16. Check the O-ring on the transmission drain plug for tears, cuts or general deterioration. Replace as necessary.
17. Install transmission drain plug. Tighten the plug to 14-21 ft-lbs (19-28 Nm).
18. Remove the transmission lubricant filler plug from the right side of the transmission case. Inspect the O-ring for cuts, tears or general deterioration. Replace the O-ring if necessary.
19. Pour 32 oz. (946 ml) of transmission lubricant through the fill hole. Use only Harley-Davidson FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-RICANT, Part No. 99851-05 (quart).
20. With the motorcycle resting on the jiffy stand on level ground, insert the filler plug into the fill hole so that it is resting on the threads. Do not screw the filler plug into the fill hole. Remove the filler plug and note the level of the lubricant on the dipstick. Lubricant level should be between the A(dd) and F(ull) marks.
1
2
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1. Outer ramp tab and slot 2. Retaining ring gap
Figure 2-90. Assemble Clutch Release Cover
1 6
4 3
2 5
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Figure 2-91. Clutch Release Cover Torque Sequence (Short Screws at Locations 1 and 6)
21. Install the filler plug in the transmission case and tighten to 25-75 in-lbs (2.8-8.5 Nm).
22. Adjust the clutch cable. See 1.11 CLUTCH.
23. Install right side exhaust system. See 4.18 EXHAUST SYSTEM.
24. Install maxi-fuse. See 8.5 SYSTEM FUSES AND RELAYS.
2.24 HANDLEBARS
ADJUSTMENT
1. Remove maxi-fuse. See 8.5 SYSTEM FUSES AND RELAYS.
2. Gain access to upper handlebar clamp:
a. FLHR/C: Remove decorative plate from handlebar clamp shroud. See Figure 2-92 and Figure 2-93.
b. FLHX, FLHT/C/U: Remove fairing cap. See 2.36 FAIRING CAP: FLHX, FLHT/C/U.
c. FLTR: Remove instrument bezel. See 2.40 INSTRUMENT BEZEL: FLTR.
3. Loosen rear screws on the upper handlebar clamp. On FLTR models, loosen the front screws instead.
4. Position handlebars for rider posture and comfort.
5. To be sure that the handlebars are centered, verify that the knurled area on the outboard side of the left side handlebar clamp is equal to that on the right side.
6. Snug upper handlebar clamp screws.
7. Slowly turn handlebars to the full right fork stop and then the full left fork stop to be sure there is no contact with the fuel tank. If contact occurs and handlebars are properly aligned, raise handlebars as necessary until the proper clearance is obtained.
8. Tighten the upper handlebar clamp screws to 16-20 ft-lbs (21.7-27.1 Nm).
9. Reassemble:
a. FLHR/C: Install decorative plate onto handlebar clamp shroud. See Figure 2-92.
b. FLHX, FLHT/C/U: Install fairing cap. See 2.36 FAIRING CAP: FLHX, FLHT/C/U.
c. FLTR: Install instrument bezel. See 2.40 INSTRU-MENT BEZEL: FLTR.
10. If necessary, adjust left and right handlebar switch controls as follows:
a. Loosen two screws securing handlebar clamp to clutch lever bracket (left) or master cylinder reservoir (right).
b. Position switch controls for rider posture and comfort.
c. Beginning with top screw, tighten screws securing handlebar clamp to clutch lever bracket to 72-108 in-lbs (8-12 Nm).
d. Beginning with top screw, tighten screws securing handlebar clamp to master cylinder reservoir to 72-80 in-lbs (8-9 Nm).
11. Install maxi-fuse. See 8.5 SYSTEM FUSES AND RELAYS.
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Figure 2-92. Remove Decorative Plate (FLHR/C)
sm03838
Figure 2-93. Loosen Upper Handlebar Clamp Screws (FLHR/C)
REMOVAL
1. Remove maxi-fuse. See 8.5 SYSTEM FUSES AND RELAYS.
2. Remove or disconnect twist grip sensor jumper harness depending upon whether the handlebar is being replaced or just removed. See 4.9 TWIST GRIP SENSOR.
3. Place blanket or protective cover over front of fuel tank to protect against scratches or other damage.
4. Gain access to upper handlebar clamp:
a. FLHR/C: Remove handlebar clamp shroud. See 2.45 HEADLAMP NACELLE: FLHR/C.
b. FLHX, FLHT/C/U: Remove fairing cap. See 2.36 FAIRING CAP: FLHX, FLHT/C/U. Remove radio (or storage box). See 8.32 ADVANCED AUDIO SYSTEM.
c. FLTR: Remove instrument nacelle. See 2.41 INSTRUMENT NACELLE: FLTR.
5. Remove right and left handlebar switch controls. See 8.39 HANDLEBAR SWITCH ASSEMBLIES and 8.39 HANDLEBAR SWITCH ASSEMBLIES, respectively.
6. Remove upper handlebar clamp screws. Remove upper handlebar clamp and handlebar.
INSTALLATION
1. Place new handlebars on lower handlebar clamps. Install upper handlebar clamp and loosely install clamp screws.
2. To be sure that the handlebars are centered, verify that the knurled area on the outboard side of the left side handlebar clamp is equal to that on the right side.
3. Snug upper handlebar clamp screws.
4. Slowly turn handlebars to the full right fork stop and then the full left fork stop to be sure there is no contact with the fuel tank. If contact occurs and handlebars are properly aligned, raise handlebars as necessary until the proper clearance is obtained.
5. Tighten upper handlebar clamp screws as follows:
a. Tighten front screws until upper and lower handlebar clamps make contact.
b. Tighten rear screws to 16-20 ft-lbs (21.7-27.1 Nm).
c. Tighten front screws to 16-20 ft-lbs (21.7-27.1 Nm).
NOTE
A slight gap will exist between the upper and lower clamps at the rear of the handlebars after tightening.
6. Install left hand grip, if removed. See 2.24 HANDLEBARS, Left Hand Grip.
7. Install right and left handlebar switch controls. See 8.39 HANDLEBAR SWITCH ASSEMBLIES and 8.39 HANDLEBAR SWITCH ASSEMBLIES, respectively.
8. Reassemble:
a. FLHR/C: Install handlebar clamp shroud. See 2.45 HEADLAMP NACELLE: FLHR/C.
b. FLHX, FLHT/C/U: Install fairing cap. See 2.36 FAIRING CAP: FLHX, FLHT/C/U. Install radio (or storage box). See 8.32 ADVANCED AUDIO SYSTEM.
c. FLTR: Install instrument nacelle. See 2.41
INSTRU-11. Turn Ignition/Light Key Switch to IGNITION and test each handlebar switch for proper operation.
12. Apply front brake hand lever to test operation of brake lamp. 2. Upper clamp 3. Lower clamp 4. Cup washer 5. Spacer
6. Rubber bushing 7. Bolt
8. Ground cable (left clamp only) 9. Flat washer (right clamp only) 10. Large flat washer (right clamp only)
Figure 2-94. Handlebar Clamp Assemblies