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Old 09-03-2009, 12:04 PM   #1 (permalink)
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Question Clutch Assembly removal and starter jackshaft bushing on my 2005 Road King Classic?

On my 2005 Road King Classic I have to change the transmission shift lever behind the primary case. Can anyone help me on a question on clutch removal as a unit? In the repair book it says remove Retaing ring, release plate ,locknut and adjuster screw on the clutch and remove together with the compensating sprocket and primary chain. But if I remember correctly from when I did work on my FLHS the clutch does not just slide off the mainshaft and you had to tap it in some way. Can anyone tell me if there is a certain procedure that has to be applied here.
Also do you need a special tool to remove the starter jackshaft bushing and lip seal in the inner primary? I might as well change these while I'm at it.
Thanks for any help!
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Old 09-04-2009, 02:41 AM   #2 (permalink)
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The clutch hub should pull straight out off the splines. You may have to push then pull or gently wriggle it or tap it with a rubber/wooden mallet, but it should give way with minor effort.

No special tools should be needed for the jackshaft seal. You can tap it out with the right diameter socket or pvc pipe and install it the same ensuring you only apply pressure on the OD of the seal.

Unless the teflon coating on the Jackshaft bushing is scored, I would leave it alone. There are two bushings, a large one in the inner primary and a smaller one in the primary cover. You can remove them with a blind bearing puller, but likely you don't have one laying around. I have cut the smaller bushing in the primary cover with a hacksaw blade and some patience. It was scored down to the brass. There is a small channel between the bushing and the primary cover that allows it to be cut thru without cutting into the cover. The bushing then splits apart easily. If you don't have access to a press you can install the bushing by tapping in with the right size diameter pipe/socket. Ensure you get it straight on. Take note of the depth of the original bushing to properly set the new one.

Follow the SM when pulling the inner primary in order not to damage the inner primary mainshaft seal if it is still good. You will need a new O ring for the stator hole and RTV for the bolts. Some guys replace all seals and bearings when pulling the inner primary, others like me, only replace what is leaking or bad. Personal choice. Good luck.
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Old 09-04-2009, 05:57 AM   #3 (permalink)
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Thanks

Thanks alot, it does not sound too complicated I was worried about special tools but it seems I don't need them.
Thanks again,
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