HARLEY DAVIDSON FLHRC 2006 REPAIR MANUAL

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Bearings
Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a non-flammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings. Coat bearings with clean oil. Wrap bearings in clean paper. Be sure that the chamfered side of the bearing always faces the shoulder (when bearings installed against shoulders). Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Always use the proper tools and fixtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary.

Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement. Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings. Always discard seals after removal. Do not use the same seal twice.

O-Rings (Preformed Packings)
Always discard O-rings after removal. Replace with new Orings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.

Gears
Always check gears for damaged or worn teeth. Remove burrs and rough spots with a honing stone or crocus cloth before installation. Lubricate mating surfaces before pressing gears on shafts.

Bushings
Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out bushings that must be replaced. When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, flat end. Never use a hammer to drive bushings. Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned.

Shafts
If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force. Shafts fitted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly. Clean all rust from the machined surfaces of new parts.

Part Replacement Gaskets
Always discard gaskets after removal. Replace with new gaskets. Never use the same gasket twice (unless instructed otherwise). Be sure that gasket holes match up with holes in the mating part. If a gasket must be made, be sure to cut holes that match up with the mating part. Serious damage can occur if any flange holes are blocked by the gasket. Use material that is the right type and thickness. Always replace worn or damaged parts with new parts.

CLEANING
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected.

Lip Type Seals
Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications.

Cleaning Process
Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting.

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Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted.

Bearings
Remove shields and seals from bearings before cleaning. Clean bearings with permanent shields and seals in solution. Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine. Let bearings stand and dry. Do not dry using compressed air. Do not spin bearings while they are drying.

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TOOL SAFETY
AIR TOOLS
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PUNCHES/CHISELS
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Never use a punch or chisel with a chipped or mushroomed end; dress mushroomed chisels and punches with a file. Hold a chisel or a punch with a tool holder if possible. When using a chisel on a small piece, clamp the piece firmly in a vise, and chip toward the stationary jaw. Wear approved eye protection when using these tools. Protect bystanders with approved eye protection.

Always use approved eye protection equipment when performing any task using air-operated tools. On all power tools, use only recommended accessories with proper capacity ratings. Do not exceed air pressure ratings of any power tools. Bits should be placed against work surface before air hammers are operated. Disconnect the air supply line to an air hammer before attaching a bit. Never point an air tool at yourself or another person. Protect bystanders with approved eye protection.

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SCREWDRIVERS
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Don't use a screwdriver for prying, punching, chiseling, scoring, or scraping. Use the right type of screwdriver for the job; match the tip to the fastener. Don't interchange POZIDRIV®, PHILLIPS®, or REED AND PRINCE screwdrivers. Screwdriver handles are not intended to act as insulation; don't use on live electrical circuits. Don't use a screwdriver with rounded edges because it will slip ­ redress with a file.

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WRENCHES
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Never use an extension on a wrench handle. If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go. Never cock a wrench. Never use a hammer on any wrench other than a Striking Face wrench. Discard any wrench with broken or battered points. Never use a pipe wrench to bend, raise, or lift a pipe.

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RATCHETS AND HANDLES
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Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit. Never hammer or put a pipe extension on a ratchet or handle for added leverage. Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism. When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet's gear wheel is engaged with the pawl.

PLIERS/CUTTERS/PRYBARS
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Plastic or vinyl covered pliers handles are not intended to act as insulation; don't use on live electrical circuits. Don't use pliers or cutters for cutting hardened wire unless they were designed for that purpose. Always cut at right angles. Don't use any prybar as a chisel, punch, or hammer.

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HAMMERS
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SOCKETS
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Never strike one hammer against a hardened object, such as another hammer. Always grasp a hammer handle firmly, close to the end. Strike the object with the full face of the hammer. Never work with a hammer which has a loose head. Discard hammer if face is chipped or mushroomed. Wear approved eye protection when using striking tools. Protect bystanders with approved eye protection.

Never use hand sockets on power or impact wrenches. Select the right size socket for the job. Never cock any wrench or socket. Select only impact sockets for use with air or electric impact wrenches. Replace sockets showing cracks or wear. Keep sockets clean. Always use approved eye protection when using power or impact sockets.

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