User manual | INSTRUCTIONS - Harley

INSTRUCTIONS
®
REV. 10-06-2004
-J03551
Kit Number 36822-04
SE HYDRAULIC CLUTCH SECONDARY ACTUATOR CYLINDER SERVICE KIT
General
This kit is designed to service the hydraulic clutch secondary
actuator (slave) cylinder for the Screamin’ Eagle 6-Speed
hydraulic side cover.
NOTE
To prevent the possibility of fluid leakage, the cover gasket
MUST be replaced each time the cover is removed. A
replacement gasket, Part Number 35148-03 is available separately from your Harley-Davidson Dealer.
See the Service Parts list for kit contents.
For some models, the right-side exhaust system will
need to be removed. In most cases, you will need to
perform at least the following:
a. Loosen, but do not remove the front and rear header
pipes at the cylinder heads.
b. Loosen the exhaust support bracket at the starter.
c. Loosen the exhaust system heat shields as needed
to access the transmission side cover screws.
d. Remove the clamp holding the rear exhaust pipe to
the transmission bracket. Set aside for re-installation.
e. Remove and retain the two bolts and lockwashers
attaching the right-side muffler to the rear bracket.
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 HarleyDavidson dealer perform the installation. Improper
installation of this kit could result in death or serious
injury. (00333a)
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)
NOTE
A Service Manual for your model and year motorcycle is
available from your Harley-Davidson Dealer.
4. Remove the magnetic drain plug at the bottom-right side
of the oil pan, and drain the transmission lubricant into a
suitable container.
Removing the Existing Components
Support the motorcycle securely on the jiffy stand on a firm,
level surface.
5. Remove and retain the filler plug/ dipstick for later installation See Figure 1. Remove and retain the six sockethead screws with washers (4 and 5) to free the transmission side cover (1) from the transmission case.
1WARNING
6. Actuate the clutch lever to break the cover seal. Remove
the cover. Remove and discard the cover gasket (2).
CAUTION
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)
1WARNING
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.
2. Remove the right-side saddlebag, if so equipped. Refer
to SADDLEBAG REMOVAL in the Service Manual.
3. To access the transmission side cover assembly, see
EXHAUST SYSTEM REMOVAL in the Service Manual.
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1. Transmission side cover
2. Cover gasket
3. Clutch fluid line
4. Short screw (4)
5. Long screw (2)
Figure 1. Transmission Side Cover Removal
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CAUTION
Remove clutch fluid lines carefully. Damage to seating
surfaces can cause leakage. (00327a)
5. Place a new cover gasket (H-D Part Number 35148-03)
over the hollow locating pins in the transmission housing. Line up the clutch-release cover on the locating
pins.
7. Disconnect the clutch-fluid line fitting from the transmission side cover. Direct the line into a suitable container
to catch any fluid that leaks out.
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1WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
Wear safety glasses when working with compressed air.
Never use your hand to check for air leaks or to determine air flow rates. (00061a)
8. See the Service Parts illustration. Use an air hose to
remove the hydraulic clutch piston.
• Use a tapered, rubber-tipped nozzle on the air hose to
prevent loss of air pressure or damage to the threads.
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4
3
5
2
• Apply low pressure compressed air to the fluid line
fitting hole to remove the piston from the transmission
side cover bore.
• Wiggle the piston while pulling it from the bore for best
results.
• Discard the old piston and spring.
Installing the New Components
1WARNING
Use denatured alcohol to clean clutch system components. Do not use mineral-based solvents (such as
gasoline or paint thinner), which will deteriorate rubber
parts even after assembly. Deterioration of these components can cause clutch failure, which could result in
death or serious injury. (00296a)
1. Clean the inside of the transmission side cover bore
with denatured alcohol. Wipe dry with a clean, lint-free
cloth. Blow out the bore and fluid passage with a clean
air supply. Do not use a wire or similar instrument to
clean the passage.
2. Inspect the piston bore, and replace the transmission
side cover if the bore shows signs of pitting or corrosion.
Do not hone the bore for re-use.
3. Inspect the new piston, seal and wiper assembly and
the new spring for dirt or damage. Apply the lubricant
from the kit to the following areas before assembly:
• the nose radius and outside diameter of the piston,
• the outside diameter of the seal and wiper,
• the inside of the piston bore.
CAUTION
Avoid leakage. Prevent damage to piston or piston bore.
Use non-metallic tools when servicing clutch actuator.
(00328a)
Figure 2.Transmission Side Cover Screw Torque
Sequence
6. Loosely install the two 2-1/4 inch (57 mm) long screws
(removed earlier) into the top two holes in the cover.
Loosely install the four 1-1/2 inch (38 mm) long screws
into the remaining four holes.
7. Refer to Figure 2. Tighten the cover screws, in the
sequence shown, to 120-144 in-lbs (14-16 Nm).
8. Assemble the clutch-fluid line fitting to the transmission
side cover. Torque the fitting to 80-115 in-lbs (9-13 Nm).
NOTE
Position the clutch-fluid line to be at least 1/2 inch (12.7 mm)
from the exhaust heat shield and at least 1 inch (25.4 mm)
from the muffler or exhaust pipe.
Bleeding the Clutch Fluid Line
NOTE
Hydraulic Brake Fluid is referred to as clutch fluid in these
instructions and in the Service Manuals. Do not use other
types of fluid or mix fluids as they are not compatible. Refer
to your owners manual for information on the correct
hydraulic brake fluid for your model motorcycle.
1CAUTION
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)
4. Place the new spring inside the piston, seal and wiper
assembly. Carefully insert the piston by hand into the bore
of the transmission side cover. If the installation shows
resistance, remove the piston and check that the seals
and wipers are properly seated, and the spring is in place.
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1CAUTION
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)
1. Refer to service manual or owners manual to determine
the appropriate brake fluid. The master cylinder cover
label lists the appropriate fluid as well.
14. 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.
15. Install the cover (with gasket) on the master-cylinder
reservoir so that the thicker side is positioned above the
clutch-line fitting. Fasten the cover to the reservoir with
two Phillips screws. Tighten the screws to 6-8 in-lbs
(0.7-0.9 Nm).
2. 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.
i04889a
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CAUTION
4
Do NOT allow dirt or debris to enter the clutch master
cylinder reservoir. Dirt or debris in the reservoir can
cause improper operation of the clutch and equipment
damage. (00205a)
3. Stand the motorcycle upright so that the master cylinder
is in a level position. Remove the master-cylinder cover
and gasket.
NOTE
DO NOT OVERFILL.
4. Add the appropriate type of brake fluid on 2005 Touring
Models) to the master-cylinder reservoir until the fluid
level is at or just below the fill line. Do not reuse old
fluid. Only use fluid from a sealed container.
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6
1.
2.
3.
4.
5.
6.
Primary chaincase
Pushrod
Clutch release plate
Clutch cover seal
Derby cover
Cover screw (5)
Figure 3. Clutch Inspection Cover
5. Activate the clutch lever 5-10 times.
6. 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.
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.
7. Once fluid exits the bleeder, close the bleeder valve.
NOTE
DO NOT OVERFILL.
8. If necessary, add additional clutch fluid to the master
cylinder reservoir until the fluid level is at or just below
the fill line.
9. Depress and hold the clutch hand-lever to build up
hydraulic pressure.
10. 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.
11. Repeat Steps 7 through 9 until all air bubbles are purged.
12. Tighten the bleeder valve to 80-100 in-lbs (9.0-11.3
Nm) and install the bleeder cap.
13. Again, if necessary, add clutch fluid to the master cylinder reservoir until the fluid level is at or just below the fill
line.
-J03551
Removing the Clutch-Inspection Cover
NOTE
Standing the motorcycle upright is required so fluid doesn’t
spill. Ensure that the vehicle is supported securely.
1. If necessary, remove the left-side passenger footpeg or
footboard.
2. See Figure 3. Using a T27 TORX drive head, remove
the clutch-inspection (derby) cover (5) from the primary
chaincase (1).
Measuring Clutch Plate Lift
1. Attach the standoff of a dial indicator to one of the 1/4-20
clutch-inspection (derby) cover mounting holes. Position
the anvil to the end of the push rod.
1WARNING
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)
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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).
e. Using a T27 TORX drive head, alternately tighten
screws to 84-108 in-lbs (10-12 Nm) in the pattern
shown in Figure 4.
Final Assembly
IMPORTANT
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
1. Check the “O”-ring on the transmission drain plug
removed earlier for tears, cuts or general deterioration,
and replace if necessary.
2. Install the drain plug and torque to 14-21 ft-lbs (19-28 Nm).
CAUTION
Do not over-tighten drain plug. Doing so could result in
a lubricant leak. (00200a)
Models with Quad Ring Seal
1. See Figure 3. Remove the quad-ring clutch-inspection
cover seal (4) (2004 and later models use a gasket, H-D
Part Number 25416-99C) from the groove in the primary
chaincase cover. Wipe all lubricant from the seal and
inspect it for cuts, tears or signs of deterioration.
Replace if necessary.
3. Fill the transmission with the proper transmission lubricant.
See the MAINTENANCE section of the Service Manual.
4. Check the “O”-ring on the filler plug/ dipstick for tears,
cuts or general deterioration, and replace if necessary.
Install the filler plug/dipstick into the clutch-release cover.
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CAUTION
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Figure 4. Torque Sequence, Primary Chaincase Cover
2. Swab all lubricant from the quad-ring groove (2004 and
later models use a gasket, H-D Part Number 2541699C)). Install the seal into the groove with the nubs contacting the groove walls.
3. Using a T27 TORX drive head, install the derby cover to
the primary-chaincase cover with the five screws (with
captive washers) removed earlier.
4. See Figure 4. Tighten the derby cover screws, in the
sequence shown, to 84-108 in-lbs (10-12 Nm).
Models with Clutch Inspection Cover Gasket
1. To avoid punching holes in the clutch inspection cover
gasket or enlarging existing holes, install clutch inspection cover and new gasket as follows:
Be sure exhaust pipes do not contact frame or components. Contact will transmit vibration to the rider.
(00348a)
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
removed should be replaced with new parts.
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)
6. Connect the battery cables, positive cable first.
7. Refer to the Service Manual, and follow instructions to
install the seat.
1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat
can shift causing loss of control, which could result in
death or serious injury. (00070a).
8. Test ride the motorcycle. If the clutch does not work
properly, it may be necessary to re-bleed the clutch-fluid line.
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).
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®
Service Parts
Part Number 36822-04
Date 10/04
Hydraulic Clutch Slave Cylinder Service Kit
i05104
Item
1
2
3
-J03551
Description
Part Number
Piston, seal and wiper
assembly
Spring
Lubricant
Not sold
Not sold
Not sold
1
3
2
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