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SPECIFICATIONS 7.1
Table 7-1. Transmission Data Table 7-2. Internal Gear Ratios
TRANSMISSION DATA GEAR INTERNAL GEAR RATIOS
5-speed forward - First 3.21
Type
constant mesh
Second 2.21
Quart Part No.
SYN3 99824-03/00QT Third 1.57
24 oz. Fourth 1.23
Capacity (dry)
710 ml Fifth 1.00
Approximately
Capacity (wet) 20-24 oz.
590-710 ml
2004 FLHTCSE: Transmission 7-1
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SERVICE WEAR LIMITS 7.2
Table 7-3. Shifter Forks Table 7-6. Countershaft
SHIFTER FORKS IN. MM COUNTERSHAFT
IN. MM
TOLERANCE
Shifter fork to cam
0.0017-0.0019 0.043-0.048
groove end play Countershaft runout 0.000-0.003 0.00-0.08
Shifter fork to gear Countershaft end play none none
0.0010-0.0110 0.025-0.279
groove end play 1st gear clearance 0.0003-0.0019 0.008-0.048
1st gear end play 0.0050-0.0039 0.127-0.099
Table 7-4. Mainshaft
2nd gear clearance 0.0003-0.0019 0.008-0.048
MAINSHAFT
IN. MM 2nd gear end play 0.0050-0.0440 0.127-1.118
TOLERANCE
3rd gear clearance 0.0000-0.0080 0.000-0.203
Mainshaft runout 0.000-0.003 0.000-0.08
4th gear clearance 0.0000-0.0080 0.000-0.203
Mainshaft end play none none
4th gear end play 0.0050-0.0390 0.127-0.991
1st gear clearance 0.0000-0.0080 0.000-0.203
5th gear clearance 0.0000-0.0080 0.000-0.203
2nd gear clearance 0.0000-0.0800 0.000-2.032
5th gear end play 0.0050-0.0040 0.127-0.102
3rd gear end play 0.0050-0.0420 0.127-1.067
3rd gear clearance 0.0003-0.0019 0.008-0.048
Table 7-7. Shifter Dogs
4th gear end play 0.0050-0.0310 0.127-0.787
SHIFTER DOG MINIMUM MAXIMUM
4th gear clearance 0.0003-0.0019 0.008-0.048 GEARS CLEARANCE CLEARANCE
0.035 in. 0.139 in.
Table 7-5. Main Drive Gear (5th) 2nd-5th
0.89 mm 3.53 mm
MAIN DRIVE
IN. MM 0.035 in. 0.164 in.
GEAR (5TH)
2nd-3rd
0.89 mm 4.17 mm
Bearing fit in
transmission case 0.0003-0.0017 0.008-0.043 0.035 in. 0.152 in.
(loose) 1st-4th
0.89 mm 3.86 mm
Fit in bearing (tight) 0.0009 0.023
0.035 in. 0.157 in.
Fit in bearing (loose) 0.0001 0.0025 1st-3rd
0.89 mm 3.99 mm
Fit on mainshaft 0.0001-0.0009 0.0025-0.023
End play none none
Fit in side door (tight) 0.0014-0.0001 0.036-0.0025
Fit on countershaft
0.0008 0.020
(tight)
Fit on countershaft
0.00001 0.0003
(loose)
Fit on mainshaft
0.0007 0.018
(tight)
Fit on mainshaft
0.0001 0.0025
(loose)
7-2 2004 FLHTCSE: Transmission
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TORQUE VALUES 7.3
ITEM TORQUE NOTES
Bleeder valve 80-100 in-lbs 9-11 Nm page 7-5
Clutch fluid line flare nut 80-115 in-lbs 9-13 Nm page 7-5
Clutch fluid reservoir banjo bolt 17-22 ft-lbs 23-31 Nm page 7-5
Clutch fluid reservoir cover 6-8 in-lbs 0.7-0.9 Nm page 7-5
Clutch release cover 120-144 in-lbs 14-16 Nm page 7-5
Filler plug/dipstick 25-75 in-lbs 2.8-8.5 Nm page 7-5
Negative battery cable 60-96 in-lbs 6.8-10.9 Nm page 7-5
Transmission drain plug 14-21 ft-lbs 19-28 Nm page 7-5
2004 FLHTCSE: Transmission 7-3
HOME
CLUTCH RELEASE COVER 7.4
REMOVAL
9930
1. Remove filler plug/dipstick. 1
2. Place a suitable container under transmission. Remove
magnetic drain plug at bottom right of oil pan and drain
transmission lubricant. 2
3. Remove seat. See 2.13 SEAT. 3
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
proceeding. (00251a).
4. Remove negative battery cable (black) from negative (-)
battery terminal. 1. Bleeder valve (cap removed)
2. Flare nut
5. Remove the right side of the exhaust system. See 3. Clutch fluid line
EXHAUST in the Touring Models Service Manual.
6. See Figure 7-1. Place a suitable container under clutch Figure 7-1. Clutch Release Cover
release cover. Remove cap and open bleeder valve and (exhaust system removed)
loosen flare nut and allow clutch fluid to drain.
7. Remove flare nut on outside of the clutch release cover. 9923
Remove clutch fluid line and drain line.
IMPORTANT NOTE 2
Dispose of clutch fluid in accordance with local regula- 1
tions. 1
8. See Figure 7-3. Remove o-ring on end of clutch fluid
line. Discard o-ring.
NOTE
Clutch fluid line o-ring may stick to inside of clutch release
cover. Use a pick to remove old o-ring and other debris.
9. Remove clutch release cover fasteners, cover and gas-
ket.
10. Clean and inspect clutch release cover. Clean with
denatured alcohol or D.O.T. 5 SILICONE BRAKE FLUID,
1. Hole for locating dowel
only.
2. Secondary clutch actuator
NOTE
If required, replace locating dowels in transmission side door. Figure 7-2. Inside Clutch Release Cover
11. See Figure 7-2. Disassemble and inspect secondary
clutch actuator. Rebuild if required. See 7.5 SECOND-
ARY CLUTCH ACTUATOR.
7-4 2004 FLHTCSE: Transmission
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INSTALLATION
9994
1. Place a new clutch release gasket on locating dowels
and position clutch release cover on transmission side
door.
2. Install fasteners with the two short fasteners at the top of
the release cover. Tighten fasteners to 120-144 in-lbs
(14-16 Nm).
3. See Figure 7-3. Install a new clutch fluid line o-ring on
the end of the clutch fluid line.
4. Install clutch fluid line flare nut to clutch release cover.
Tighten to 80-115 in-lbs (9-13 Nm).
5. Loosen bleeder valve.
1WARNING Figure 7-3. Clutch Fluid Line O-ring
Be sure NO clutch fluid gets on rear tire, wheel or brakes
8. Tighten fasteners as follows:
when adding clutch fluid. Traction will be adversely
affected which could result in loss of control of the a. Reservoir banjo bolt to 17-22 ft-lbs (23-31 Nm).
motorcycle and death or serious injury.
b. Bleeder valve to 80-100 in-lbs (9-11 Nm).
c. Reservoir cover screws to 6-8 in-lbs (0.7-0.9 Nm).
1WARNING
9. Install bleeder valve cap.
Do NOT allow foreign matter to enter the clutch master
cylinder reservoir. Dirt or debris in the reservoir may 10. Inspect o-ring on transmission lubricant drain plug and
cause improper operation of the clutch and equipment replace as necessary. Install drain plug and tighten to
damage. 14-21 ft-lbs (19-28 Nm).
11. Fill the transmission with 20-24 oz. (590-710 ml) of
1WARNING transmission lubricant or until the lubricant level on the
dipsitck of the filler plug is at the F (full) mark with the
Direct contact of D.O.T. 5 SILICONE BRAKE FLUID with motorcycle level and upright and the filler plug resting on
eyes may cause eye irritation, swelling, and redness. the threads. Use only Harley-Davidson TRANSMISSION
Avoid eye contact. In case of eye contact flush with large LUBRICANT, Part No. 98853-96 (case/quarts), or Part
amounts of water and seek medical attention immedi- No. 98852-96 (case/gallons).
ately. Swallowing large amounts of D.O.T. 5 SILICONE
12. Inspect the filler plug/dipstick o-ring and install filler plug/
BRAKE FLUID may cause digestive discomfort. If swal-
dipstick. Tighten the plug to 25-75 in-lbs (2.8-8.5 Nm).
lowed, seek medical attention immediately. Use in well
ventilated area. KEEP OUT OF REACH OF CHILDREN. 13. Install exhaust system. See EXHAUST in Touring Mod-
els Service Manual.
1WARNING 14. Install negative battery cable. Tighten bolt to 60-96 in-
lbs (6.8-10.9 Nm).
The piston in the secondary clutch actuator is under
pressure. Squeezing the clutch hand lever could force 15. Install seat. See 2.13 SEAT.
the piston out of its housing with sufficient force to
cause death or serious injury.
6. Remove clutch fluid reservoir cover and fill with D.O.T. 5
SILICONE BRAKE FLUID. Allow fluid to fill clutch line
until a steady flow of clutch fluid flows from bleeder
valve. Tighten bleeder valve.
NOTE
When filling an empty clutch fluid line, a Snap-on BASIC
VACUUM BRAKE BLEEDER with a fitting that mates to the
bleeder valve threads can be used to initially draw the fluid
down the clutch line with little or no air in the line.
7. Bleed clutch fluid line. See BLEEDING CLUTCH FLUID
LINE.
2004 FLHTCSE: Transmission 7-5
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SECONDARY CLUTCH ACTUATOR 7.5
REBUILD
8880
1. Remove the clutch release cover. See 7.4 CLUTCH 1 2
RELEASE COVER.
1WARNING
3
Pressurized air can blow debris into your face and eyes.
Always wear eye protection or a face shield when using
pressurized air. Failure to take adequate safety precau-
tions could result in death or serious injury.
2. Remove piston.
a. If the bleeder valve was removed, reinstall.
b. Support on a wooden block and apply low pressure
compressed air to clutch fluid line hole to remove
piston from cover bore.
1. Piston
3. See Figure 7-4. If necessary, wiggle piston from actuator 2. Primary cup
bore to completely remove. 3. Spring
4. Remove the spring. Discard spring and piston assembly. Figure 7-4. Secondary Clutch Actuator Components
CAUTION
Damaged pistons or piston bores will leak when reas-
sembled. Do not use metal objects to remove or install
objects from piston bores. Prevent damage to bores by
only using a wooden toothpick when servicing second-
ary clutch actuator.
5. Lubricate new piston assembly and piston bore with the
service kit lubricant.
6. Install new spring.
7. While pushing piston into actuator bore, use a wooden
tooth pick or the end of a cable wrap to prevent primary
cup from rolling over.
7-6 2004 FLHTCSE: Transmission
