Elements of transmission motorcycle Harley V-Rod VRSCA (2002-2006)

Clutch — removal
Figure 3-77. Clutch: 1. Retaining ring; 2. Contact button; 3. Lifter guide; 4. Lifter plate; 5. Oil retaining ring; 6. Clutch hub; 7. Damper spring seat; 8. Damper spring; 9. Pressure plate spring (5); 10. Friction plate (9); 11. Separator plate...

Clutch — disassembly
1. Use a marker to mark clutch basket and clutch pack for assembly. 2. See Figure 3-87. Remove clutch pack from clutch basket. Figure 3-87. Remove clutch pack 3. See Figure 3-88. To prevent breaking lifter plate, slowly loosen (2-3 turns at a time)...

Clutch — cleaning and inspection
Warning! Low pressure compressed 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 precautions could result in death or serious injury. 1. Wash all...

Clutch — assembly
PART NO. SPECIALTY TOOL HD-45654 Clutch disc aligning spacer HD-45318 Clutch hub holder 1. See Figure 3-90. Place flat steel damper spring seat on the clutch outer hub. Position the damper spring on the damper spring seat with concave side up....

Clutch — installation
1. See Figure 3-103. Separate clutch pack from the clutch shell. Figure 3-103. Clutch pack 2. See Figure 3-104. Check position of thrust washer. Figure 3-104. Thrust washer position 3. See Figure 3-105. Slide clutch basket on to the input shaft....

Gearbox specifications
Table 7-1. Primary gearing ENGINE OUTPUT TRANSMISSION INPUT RATIO 64 117 1.828 Table 7-2. Transmission gearing GEAR INPUT OUTPUT RATIO 1st 18 45 2.500 2nd 25 42 1.680 3rd 29 39 1.345 4th 31 36 1.161 5th 25 26 1.040 Table 7-3. Secondary gearing...

Output shaft disassembly — 2nd gear end
This procedure starts with the input shaft and output shaft removed from the engine. See 3.11 Upper and lower crankcase service for removal of input shaft and output shaft. Bearing removal - 2nd gear end PART NO. SPECIALTY TOOL HD-45331 Final drive...

Output shaft assembly — 2nd gear end
1. See Figure 7-17. Install 5th gear ground washer and split cage bearing. Figure 7-17. 5th gear installation 2. See Figure 7-18. Install 2nd gear. Note 2nd gear pockets are installed toward the 5th gear engagement dogs. Figure 7-18. 2nd gear...

Output shaft assembly — 1st gear end
Carefully clean and inspect parts to be reused. Examine gears for cracks, chipping and excessive wear. 1. See Figure 7-29. Install split cage needle bearing. Install 3rd gear. Figure 7-29. 3rd gear 2. See Figure 7-30. Install half moon keepers....

Input shaft disassembly — 2nd gear end
Bearing removal - 2nd gear end Warning! Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring...

Input shaft assembly — 2nd gear end
1. See Figure 7-48. Lubricate new split cage bearing and position on shaft. Install 4th gear and place half moon keepers in position. Figure 7-48. 4th gear and keepers 2. See Figure 7-49. Insert splined slider with stepped side toward 4th gear....