Automatic Primary Chain Tensioner Instruction - Harley
Contents
1. Item Description Quantity Part Number 1 Carriage bolt 3 8 16 X 1 1 4 in 5416 use for 1985 2000 models only 2 Screw hex 5 16 18 X 1 1 2 in 2932A 2 Bracket autotensioner 40065 05 Autotensioner Not Sold 3 of 32. serious injury 00070b J03784 11 Refer to the appropriate Service Manual and install the seat 1 Carriage bolt 2 Autotensioner bracket Figure 3 Autotensioner Bracket Nut and washer Autotensioner Hex screw 2 BON T Shipping plate Figure 4 Autotensioner CARE amp MAINTENANCE Removing the Autotensioner for Service 1 Use a tie wrap and secure the shoe to the base of the autotensioner without securing it to the autotensioner bracket This will retain the autotensioner adjustment for reinstallation during service 2 Remove two autotensioner hex screws and autotensioner Resetting the Autotensioner 1 See Figure 5 Compress autotensioner wedge 1 and spring back to the base 2 Hold wedge in position by inserting a hex wrench or pick tool through the hole in the base of the autotensioner 3 See Figure 6 Move plastic autotensioner shoe 1 into place as shown 4 If available install shipping plate 2 to secure the shoe to the base If it is not available secure the shoe to the base with a tie wrap 20f3 is00572 1 Autotensioner wedge Figure 5 Reset Autotensioner Spring and Wedge Autotensioner shoe 2 Shipping plate _ Figure 6 Install Shipping Plate or Tie Strap J03784 SERVICE PARTS is00558 Figure 7 Service Parts for Automatic Primary Chain Tensioner Kit Table 1 Service Parts
3. cMOTOR HARLEY DAVIDSON WY J03784 INSTRUCTIONS REV 2011 01 13 AUTOMATIC PRIMARY CHAIN TENSIONER GENERAL Kit Number 40063 05B Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required Proper installation of this kit requires the separate purchase of a primary cover gasket and other seals that vary depending on the model See your authorized Harley Davidson dealer for the proper parts Loctite 262 Threadlocker and Sealant red 94759 99 is required for proper installation on 1985 2000 model motor cycles AWARNING 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 a Harley Davidson Dealer Kit Contents See Figure 7 and Table 1 INSTALLATION 1 Refer to the appropriate Service Manual and remove seat IWAN IN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cabl
4. e before proceeding 00048a 2 Disconnect negative battery cable 3 Refer to the appropriate Service Manual and remove primary cover J03784 oP ONS Screw 2 Anchor plate Nut and washer Manual tensioner Screw 2 Figure 1 Manual Tensioner 1985 2000 Models For 1985 2000 model motorcycles remove manual tensioner and replace the carriage bolt as follows a See Figure 1 Remove two screws 5 and nut and washer 3 and remove chain tensioner 4 Remove two screws 1 and anchor plate 2 Replace the carriage bolt in the anchor plate with the carriage bolt from the kit Apply 2 3 drops of Loctite 262 red to the threads of the anchor plate mounting screws 1 then install anchor plate and two screws Tighten screws to 12 14 ft lbs 16 19 Nm For 2001 and later model motorcycles remove manual tensioner as follows a See Figure 2 Remove nut and washer 1 and remove chain tensioner 2 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled 1 of 3 Please dispose of materials responsibly 1 Nut and washer 2 Tensioner Figure 2 Manual Tensioner 2001 and Later 5 See Figure 3 Install the autotensioner bracket 2 over the carriage bolt 1 behind the primary chain Loosely secure the bracket using the nut and washer removed in Step 4 6 See Figure 4 Install autotensioner 2 to the autotensioner brack
5. et with two screws 3 from the kit Do not tighten screws at this time 7 See Figure 4 Position the autotensioner and bracket as follows a Carefully lift the autotensioner and bracket assembly to take the slack out of the chain b Lower the autotensioner and bracket assembly 1 2 notches to allow approximately 1 in 25 mm of chain freeplay at the top of the chain c Tighten nut 1 to 21 29 ft lbs 29 39 Nm d Tighten autotensioner hex screws 3 to 17 19 ft lbs 23 26 Nm 8 Remove tie wrap and shipping plate 4 to free the autotensioner Flex the top of the chain to allow the autotensioner to adjust itself Once the shipping plate is removed and the chain is flexed the spring loaded wedge of the autotensioner should move to the left If the shoe does not move up and down when the chain is flexed then the autotensioner bracket is positioned too high and must be lowered Install the ship ping plate or a tie wrap to secure the shoe loosen the nut and screws lower the assembly and re tighten the nut and screws according to the specifications above Then repeat this step 9 Refer to the appropriate Service Manual and install the primary cover with a new seals and refill the primary oil 10 Connect the negative battery cable AWARNING 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
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