STARTER MOUNTING BOLTS (2):
FXR2 SERVICE MANUAL PAGE 5-16
INSTALL THE TWO STARTER MOUNTING BOLTS AND WASHERS INTO THE BACK OF THE INNER PRIMARY FROM THE RIGHT SIDE OF THE BIKE. APPLY AVIATION GASKET CEMENT THEN TIGHTEN STARTER MOUNTING BOLTS TO 13-21 FT-LBS.
GROUND CABLE BOLT (1):
FXR2 SERVICE MANUAL PAGE 6-24
TO BE INSTALLED WITH APPROPRIATE WASHER AND LOCKWASHER AND TIGHTENED TO 18 - 21 FT LBS TORQUE.
STARTER JACKSHAFT:
FXR2 SERVICE MANUAL PAGE 5-27
BE SURE THE LOCKPLATE PROTRUSION IS STICKING INTO THE KEYWAY.
PAGE 5-28 LOOK AT FIGURE 5-31
TO PROPERLY INSTALL JACKSHAFT;
INSTALL JACKSHAFT LOCKPLATE AND BOLT. HOLD PINION GEAR IN PLACE AND TIGHTEN JACKSHAFT BOLT TO 84-108” IN-LBS TORQUE. BEND TAB ON LOCKPLATE AGAINST FLAT OF BOLT HEAD TO SECURE.
INSTALL COMPENSATING SPROCKET AND SHAFT EXTENSION ASSEMBLY, CHAIN, CLUTCH SHELL BASKET AS A SINGLE ASSEMBLY . THE CLUTCH HUB AND SHAFT EXTENSION ARE SPLINED, SO A SLIGHT ROTATION OF THE CHAIN DRIVE WIL AID IN THE LINING UP OF THE SPLINES.
PLACE SLIDING CAM OVER SHAFT EXTENSION. SLIDE SPROCKET COVER OVER SLIDING CAM.
PLACE TRANSMISSION IN 5TH GEAR AND APPLY REAR BRAKE.
APPLY 2 DROPS OF 262 RED LOCTITE TO THE THREADS OF THE COMPENSATING SPROCKET NUT AND TIGHTEN IN A CLOCKWISE DIRECTION 1 1/2” SOCKET 150-165 FT-LBS TORQUE.
APPLY 2 DROPS OF 262 RED LOCTITE TO THE THREADS OF THE CLUTCH SHELL BASKET HUB MAINSHAFT NUT. INSTALL NUT AND HAND TIGHTEN IN A COUNTERCLOCKWISE DIRECTION 1 3/16” SOCKET 70-80 FT LBS TORQUE.
CHAIN TENSIONER BOLTS:
FXR2 SERVICE MANUAL PAGE 1-27
FREE PLAY IN THE UPPER STRAND SHOULD BE 5/8” - 7/8” WITH COLD ENGINE
CENTER BOLT NUT: 21-29 FT LBS
CHAIN TENSIONER SHOE BOTTOM 2 BOLTS
NO TORQUE NUMBERS PROVIDED
CLUTCH SHELL BASKET/CLUTCH ADJUSTMENT:
CLUTCH ADJUSTER SCREW:
CLUTCH ADJUSTER JAM NUT TIGHTEN TO 72’-120” IN-LBS TORQUE
REAR SWING ARM PIVOT SHAFT (AXLE) INSTALLATION:
FXR2 SERVICE MANUAL PAGE 2-70
THE PIVOT SHAFT (AXLE) GETS COATED WITH ANTISEIZE
SLIDE RUBBER MOUNT (ISOLATER) ONTO PIVOT SHAFT. THE SMALL DIAMETER BOSS ON THE RUBBER MOUNT MUST FACE OUTWARD WITH THE PIN HOLD AT THE TOP (SO THAT IT ALIGNS WITH THE PIN CAST IN THE PASSENGER FOOTBOARD/REAR SWING ARM BRACKET END CAPS
SLIDE NYLON SPACER (HD# 47513-80) ONTO PIVOT SHAFT WITH SMALLER DIAMETER BOSS FACING INSIDE TOWARD THE SWING ARM.
FROM THE RIGHT SIDE OF BIKE INSERT PIVOT SHAFT (AXLE) INTO SWING ARM AND TRANSMISSION MOUNT.
ON LEFT SIDE OF BIKE, INSTALL NYLON SPACER (HD# 47513-80), RUBBER MOUNT (ISOLATOR) AND CUP WASHER ONTO PIVOT SHAFT (AXLE), INTSALL NUT UNTIL FINGER TIGHT. REMEMBER TO PROPERLY ORIENT THE LEFT SIDE RUBBER MOUNT (ISOLATOR) AND NYLON SPACER AS PREVIOUSLY DESCRIBED.
HOLD RIGHT SIDE NUT ON THE PIVOT SHAFT AND TIGHTEN LEFT SIDE PIVOT SHAFT LOCKNUT TO 40-45 FT-LBS TORQUE
OBSERVING “LEFT” AND “RIGHT” STAMP ON CASTING, INSTALL REAR SWING ARM END CAP BRACKETS FITTING THE CAST PIN IN RUBBER MOUNT (ISOLATOR) HOLE.
INSTALL TWO BOLTS WITH LOCKWASHERS TO SECURE END CAP BRACKETS TO BIKE FRAME. TIGHTEN SWING ARM END CAP BRACKET BOLTS TO 34-42 FT LBS TORQUE.
NOTE:
REMOVE THE DECORATIVE CHROME PLUGS IN THE REAR SWINGARM END CAP BRACKETS AND CHECK TORQUE ON THE PIVOT SHAFT LOCKNUT EVERY 5,000 MILES
DRIVE BELT TENSION
FXR2 SERVICE MANUAL PAGE 1-34:
CHECK THAT THE DRIVE BELT TOP STRAND DEFLECTS 3/8” - 1/2” WHILE APPLYING 10 LBS OF FORCE UPWARD
10 OUTER PRIMARY SCREWS (10): 9FT LBS
CLUTCH INSPECTION COVER/DERBY COVER (5): 9FT LBS
PRIMARY CHAIN INSPECTION COVER SCREWS (4) WHERE OUR SHIFTER COMES THROUGH: 9 FT LBS
BE CAREFUL YOU CAN STRIP THESE SCREWS EASILY 9 FT LBS IS ALSO EQUAL TO 108 IN-LBS SO DON'T EXCEED THIS MUCH.
I PERSONALLY USE AVIATION GASKET CEMENT ON MY BOLTS WHENEVER BLUE LOCTITE IS CALLED FOR AS A SUBSTITUTE TO KEEP CORROSION FROM OCCURING....IT'S A GREAT PRODUCT MADE BY PERMATEX CAN GET IT A NAPA. IT'S ALSO REFERRED TO AS FORM A GASKET....
THE OUTER PRIMARY SCREWS CAN BE STRIPPED EASILY BY CORROSION SO USING THIS PRODUCT CAN BE A TREMENDOUS BENEFIT.....