User manual | instructions - Harley

INSTRUCTIONS
®
-J03636
REV. 12-20-2004
Kit Number 38753-04A
HYDRAULIC CLUTCH SIDE COVER AND RELEASE PUSHROD KIT
General
This kit is designed to be installed along with a Hydraulic Clutch
Kit on 1999 and later Dyna models, 1999 and later FL Touring
models, and 2000 and later Softail® model motorcycles with
Twin Cam 88® engines that are equipped with a Screamin’
Eagle® 6-Speed Transmission or Screamin’ Eagle 6-Speed
Gear Set.
If installing this kit on a vehicle that has previously been
equipped with a 6-Speed Transmission or Gear Set, a
Screamin’ Eagle 6-Speed Side Cover Gasket (H-D Part
Number 35148-03) will also be needed. This gasket is
available separately from any Harley-Davidson dealer.
Harley-Davidson recommends that the clutch inspection
cover gasket, Part Number 25416-99C (sold separately), be
replaced when installing this kit. This gasket is available
separately from any Harley-Davidson dealer.
See the instructions included with the Hydraulic Clutch Kit for
a list of required additional parts.
1WARNING
The rider’s safety depends 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. (00333a)
NOTE
This instruction sheet references Service Manual information.
A Service Manual for your model motorcycle is required for
this installation and is available from any Harley-Davidson
Dealer.
2. If vehicle IS NOT currently equipped with a
hydraulic clutch:
a. Follow the instructions included with the Hydraulic
Clutch Kit.
b. Proceed to “Installing the Clutch-Release Plate”.
If vehicle IS currently equipped with a hydraulic clutch:
NOTE
Standing the motorcycle upright is required so fluid doesn’t
spill. Ensure that the vehicle is supported securely.
a. If necessary, remove the left-side passenger footpeg or footboard. Using a T27 TORX® drive head,
remove the clutch-inspection (derby) cover from the
primary chaincase.
b. See Figure 1. Remove the clutch release plate retaining ring (5) and discard. Remove the release plate (2),
adjuster rod and nut as an assembly, and discard.
c. Proceed to “Installing the Clutch-Release Plate”.
Installing the Clutch-Release Plate
1. Refer to Figure 1. Obtain the new clutch release plate
assembly (2) from the Hydraulic Clutch Kit.
NOTE
The pushrod for a 6-speed transmission has an end-to-end
length of 15.552 in (39.5 cm), and an indented “punch mark”
on the bearing end. The 5-speed pushrod is 15.213 in (38.6
cm) long and has no mark on the bearing end.
2. Discard the shorter new pushrod and small retaining ring
supplied with the Hydraulic Clutch Kit. Assemble the
clutch-release plate assembly to the new pushrod (1)
from this kit as shown, with the bearing side first. Install a
small retaining ring (3) from this kit onto the pushrod.
Removing the Existing Components
1WARNING
Perform this installation when the engine is cool.
Working on or near the exhaust system when the
engine is hot could result in severe burns. (00311a)
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1b
1WARNING
1
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect battery cables
(negative (-) cable first) before proceeding. (00307a)
1WARNING
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion,
which could result in death or serious injury. (00049a)
1. Refer to the SEAT and BATTERY sections of the
Service Manual. Remove the seat and disconnect the
battery cables, negative cable first.
1a
4
5
4
2
1a.
1b.
2.
3.
4.
5.
3
6-speed pushrod from THIS Kit
Pushrod for 5-speed (with NO punch mark)
Release plate assembly from hydraulic clutch kit
Retaining ring (small) from THIS kit
Release plate ears (2)
Retaining ring (large) from hydraulic clutch kit
Figure 4. New Clutch Release Plate Assembly
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3. Install the assembly into the clutch pressure plate. Fit
the two ears (4) into the notches in the pressure-release
plate. Push in until the clutch-release plate bottoms out
against the shoulder in the pressure plate. Install the
new large retaining ring (5) to the clutch-release plate,
and verify that the ring is fully seated.
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6
Installing the Clutch Master Cylinder
1. If vehicle IS NOT currently equipped with a
hydraulic clutch:
a. Follow the instructions included with the Hydraulic
Clutch Kit.
b. Proceed to “Installing the Transmission Side Cover”.
If vehicle IS currently equipped with a hydraulic clutch:
Proceed to “Installing the Transmission Side Cover”.
Installing the Transmission Side Cover
4
3
5
2
Figure 3. Torque Sequence, Transmission Side Cover
Installing the Clutch-Fluid Line
1. Obtain the following items:
• The new transmission side cover assembly from this kit.
• A Screamin’ Eagle 6-Speed Side Cover Gasket (H-D
Part Number 35148-03), supplied with the 6-speed
Transmission or Gear Set Kit and also sold separately.
1. If vehicle IS NOT currently equipped with a
hydraulic clutch:
a. Follow the instructions included with the Hydraulic
Clutch Kit.
b. Proceed to “Bleeding the Clutch Fluid Line”.
NOTE
The transmission side cover gasket from the Hydraulic
Clutch Kit can be discarded.
If vehicle IS currently equipped with a hydraulic clutch:
a. Remove the cap plug from the transmission side
cover if present. Install the fitting to the cover and
tighten to 80-115 in-lbs (9-13 Nm).
b. Proceed to “Bleeding the Clutch Fluid Line”.
• Two 2-1/4 inch (57 mm) long screws and four 1-1/2 in.
(38 mm) long screws from the 6-speed Transmission
or Gear Set Kit.
NOTE
The six 2-1/4 inch (57 mm) long screws from the original
cover assembly and the four 1-3/4 inch (44 mm) long screws
from the Hydraulic Clutch Kit can be discarded.
2. Refer to Figure 2. Place the new cover gasket (4) over
the hollow locating pins (5) on the transmission side door
(bearing housing). Line up the new transmission side
cover assembly (3, which includes the secondary actuator [slave] cylinder and bleeder screw) over the gasket.
3. Loosely install the two 2-1/4 in. (57 mm) long screws (1) into
the top two holes in the new cover. Loosely install four 1-1/2
in. (38 mm) long screws (2) into the remaining four holes.
4. See Figure 3. Tighten the side cover screws, in the
sequence shown, to 120-144 in-lbs (14-16 Nm).
Bleeding the Clutch Fluid Line
1. Remove the bleeder cap from the transmission side
cover bleeder valve. Install one end of a length of plastic tubing over the valve. Place the free end of the tube
in a clean container.
NOTES
D.O.T. 4 or D.O.T. 5 Silicone Hydraulic Brake Fluid is used
for the hydraulic clutch. It is referred to as clutch fluid in
these instructions and in the Service Manuals.
Refer to the Owner’s Manual to determine which type of
brake fluid is appropriate for the motorcycle. Do not use
other types of fluid, and do not mix brake fluids, as they are
not compatible.
Do not overfill the master cylinder reservoir.
1CAUTION
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4
1
2
1. Upper screw (2-1/4 inch long) (from 6-speed kit) (2)
2. New screw (1-1/2 inch long) (from 6-speed kit) (4)
3. Transmission side cover (from THIS kit)
4. Side cover gasket
Figure 2. New Transmission Side Cover Installation
-J03636
Direct contact of D.O.T. 5 brake fluid with eyes can cause
eye irritation, swelling, and redness. Avoid eye contact.
In case of eye contact flush with large amounts of water
and get medical attention. Swallowing large amounts of
D.O.T. 5 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a)
1WARNING
Direct contact of D.O.T. 4 brake fluid with eyes can
cause irritation. Avoid eye contact. In case of eye
contact flush with large amounts of water and get
medical attention. Swallowing large amounts of D.O.T.
4 brake fluid can cause digestive discomfort. If
swallowed, obtain medical attention. Use in well
ventilated area. KEEP OUT OF REACH OF CHILDREN.
(00240a)
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CAUTION
Measuring Clutch Plate Lift
D.O.T. 4 brake fluid will damage painted and molded-in
color surfaces it comes in contact with. Always use
caution and protect surfaces from spills whenever
brake work is performed. Failure to comply can result in
cosmetic damage. (00239a)
1. Attach the standoff of a dial indicator to one of the 1/420 clutch-inspection (derby) cover mounting holes.
Position the anvil to the end of the push rod.
2. See Owner’s Manual for hydraulic brake fluid
requirments. Add appropriate hydraulic brake fluid to
the master-cylinder reservoir until the fluid level is at or
just below the fill line. Do not reuse old fluid. Use only
fluid from a sealed container.
Insufficient clutch-release plate movement can lead to
difficulty or inability to shift, causing loss of control,
which could result in death or serious injury. (00345a)
3. Activate the clutch lever 5-10 times.
4. Open the bleeder valve. Clutch fluid will flow from the
bleeder valve through the tubing. It may take several
minutes for fluid to exit the bleeder.
5. Once fluid exits the bleeder, close the bleeder valve.
NOTE
DO NOT OVERFILL.
1WARNING
2. Actuate the clutch lever to measure the axial movement of
the push rod and the clutch-release plate assembly. The
axial movement needs to be at least 0.065 in. (1.65 mm).
NOTE
Proper bleeding of the system will typically yield plate movement of greater than .065 in. (1.65 mm). If clutch release
plate movement is less than .065 in., the system MUST BE
RE-BLED.
Installing the Clutch-Inspection Cover
6. If necessary, add additional clutch fluid to the master
cylinder reservoir until the fluid level is at or just below
the fill line.
1. If so equipped, remove the quad-ring clutch-inspection
cover seal from the groove in the primary chaincase
cover.
7. Depress and hold the clutch hand-lever to build up
hydraulic pressure.
NOTE
If the quad-ring clutch-inspection cover seal is not being
replaced with gasket 25416-99C as recommended,
• wipe all lubricant from the seal and inspect it for cuts,
tears or signs of deterioration.
• Swab all lubricant from the quad-ring groove.
• Install the seal into the groove with the nubs contacting the groove walls.
If the quad-ring seal is damaged, replace with gasket
25416-99C.
8. Open the bleeder valve about one-half-turn. Clutch fluid
will flow from the bleeder valve through the tubing. Close
the bleeder valve when the clutch hand-lever has moved
50% to 75% of its full range of travel. Allow the clutch
hand-lever to return slowly to its released position.
9. Repeat Steps 6 through 8 until all air bubbles are
purged.
10. Tighten the bleeder valve to 80-100 in-lbs (9.0-11.3
Nm) and install the bleeder cap.
2.To avoid punching holes in the clutch inspection cover
gasket or enlarging the existing holes, install the derby
cover and gasket as follows:
11. Again, if necessary, add clutch fluid to the master cylinder
reservoir until the fluid level is at or just below the fill line.
a. Align the triangular shaped hole in the gasket with
the top hole in the derby cover. Be sure the rubber
molding and the words “towards clutch” face the
motorcycle.
12. Verify proper operation of the master-cylinder relief port.
Actuate the clutch hand-lever. A slight spurt of fluid will
break the fluid surface in the reservoir compartment if
all internal components are working properly.
NOTE
The angular shape of the clutch master-cylinder cover
makes one side thicker than the other.
13. Obtain the clutch master-cylinder cover kit (cover,
gasket, sight glass and two Phillips screws), purchased
separately. Install the cover (with gasket) on the mastercylinder reservoir so that the thicker side is over the
clutch-line fitting.
14. Fasten the cover with the two Phillips screws. Tighten
the screws to 6-8 in-lbs (0.7-0.9 Nm).
b. Obtain one of the screws (with captive washer)
removed earlier. Insert the screw threads through the
top hole in the derby cover, and carefully thread it all
the way through the triangular shaped hole in the
gasket. Do not push the screw through the hole.
c. Hang the derby cover on the primary chaincase
cover flange by starting the top cover screw.
d. Start the remaining four screws with washers.
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4
2
3
5
NOTE
The sight glass enables the rider to visually check clutch fluid
level without removing the master-cylinder cover. When the
reservoir is full, the sight glass is dark. As the fluid level drops,
the glass lightens up to indicate this condition to the rider.
Figure 4. Torque Sequence, Primary Chaincase Cover
-J03636
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3. Using a T27 TORX drive head, alternately tighten the
screws to 84-108 in-lbs (10-12 Nm) in the sequence
shown in Figure 4.
removed should be replaced with new parts.
6. For 2004 and later FXSTS/I models: Replace the leftside turn signal mounting bracket with a new bracket
(Part Number 67355-04, purchased separately).
Final Assembly
For models with handlebar-mounted turn signals:
Install the left-side turn signal removed earlier.
1. Check the “O”-ring on the transmission drain plug
removed earlier for tears, cuts or general deterioration,
and replace if necessary.
For ALL models: Install the left-side rear-view mirror.
Adjust for proper field of vision and tighten the acorn nut
to 12 ft-lbs (16 Nm). Check mirror adjustment and reposition if necessary.
2. Install the drain plug and torque to 14-21 ft-lbs (19-28 Nm).
CAUTION
1WARNING
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
Do not over-tighten filler or drain plug. Doing so could
result in a lubricant leak. (00200b)
3. Fill the transmission with the proper transmission
lubricant. See the MAINTENANCE section of the
applicable Service Manual.
7. Refer to the Service Manual, and follow instructions to
connect the battery cables, positive cable first.
4. Check the “O”-ring on the filler plug/ dipstick removed
from the old transmission side cover for tears, cuts or
general deterioration, and replace if necessary. Install
the filler plug/ dipstick into the new transmission side
cover assembly.
8. Follow the instructions in the Service Manual to install
the seat.
1WARNING
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)
CAUTION
Be sure exhaust pipes do not contact frame or components. Contact will transmit vibration to the rider.
(00348a)
9. If necessary, install the right-side saddlebag.
5. See EXHAUST SYSTEM INSTALLATION in the
Service Manual. Re-install and tighten all exhaust-system components loosened or removed at the beginning
of the installation. Any gaskets or clamps that were
®
10. Test ride the motorcycle. If the clutch does not work
properly, it may be necessary to re-bleed the clutch fluid
line and re-measure the clutch-plate lift.
Service Parts
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Part Number 38753-04A
Date 12/04
Hydraulic Clutch Side Cover & Release Kit
i04893b
C
2
1
2a
2b
B
3
A
G
Item
1
2
3
E (2)
H
Description (Quantity)
Part Number
Transmission side cover
Pushrod, clutch release (6-speed)
(*with marked end, see inset 2a)
Retaining ring, external, 3/8 in.
38754-04A
38755-04
11143
*Note:
Plain end (see 2b) indicates shorter 5-speed pushrod,
which will not fit with 6-speed transmission.
Also available:
A
Secondary Actuator Cylinder Service Kit 36822-04
B
Bleeder screw 44613-02
C
Bleeder screw cap 43817-02
-J03636
D
F (4)
Items not included in kit:
D
6-speed side cover gasket 35148-03
E
2-1/4 in. (57 mm) long screw 4717A (2)
from 6-Speed Transmission or Gear Set Kit
F
1-1/2 in. (38 mm) long screw 4718A (4)
from 6-Speed Transmission or Gear Set Kit
G
Release plate assembly 36731-91
from Hydraulic Clutch Kit
H
Large retaining ring 37909-90
from Hydraulic Clutch Kit
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