Harley Davidson 2013 Sportster Models. Service Manual — page 41
9.
Expand and install
new
retaining ring (14).
10. Install dog ring (15). Make sure to install with dog ring
facing same direction as when it was removed.
11. Install spacer (16).
12. Install
new
split bearing (17) in 2nd gear position on shaft.
13. Install 2nd gear (18) and spacer (19).
NOTE
At this point both mainshaft and countershaft sub-assemblies
are ready to be pressed into the left crankcase half.
2
3
4
5
6
7
8
9
10
11
12
13 14
15
16
17
18
19
1
sm03376
15.
8.
1.
Dog ring
Countershaft 4th gear
Countershaft 5th gear
(integral to shaft)
16.
9.
Spacer
Retaining ring
2.
10.
Countershaft
17.
Thrust washer
Split bearing
18.
11.
3.
Countershaft 2nd gear
Split bearing
Split bearing
4.
19.
12.
Countershaft 1st gear
Spacer
Countershaft 3rd gear
13.
5.
Thrust washer
Thrust washer
6.
14.
Retaining ring
Retaining ring
7. Dog ring
Figure 5-63. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
5-38 2013 Sportster Service: Drive/Transmission
5.11
MAIN DRIVE GEAR AND BEARING
GENERAL
NOTE
See
. Main drive gear (2) removal requires
replacement of the main drive gear bearing (7 or 14). Gear
removal procedure destroys bearing's inner race.
11
1
3
4
6
14
13
12
9
10
8
7
5
2
1
sm01328
8.
1.
Countershaft bearing (closed end)
Needle bearing (2)
2.
9.
Main drive gear
Retaining ring
10.
3.
Oil seal
O-ring
4.
11.
Oil seal
Retaining ring
12.
5.
Spacer (XR 1200X)
Shifter drum bushing
6.
13.
Right crankcase
O-ring (XR 1200X)
14.
7.
Double roller bearing (XR 1200X)
Ball bearing (XL models)
Figure 5-64. Main Drive Gear and Bearing Assembly
2013 Sportster Service: Drive/Transmission 5-39
REMOVAL
TOOL NAME
PART NUMBER
CROSS PLATE
B-45847
RECEIVER CUP
HD-35316-11
BEARING DRIVER
HD-35316-13
8 INCH BOLT
HD-35316-4A
WASHER
HD-35316-7
BEARING DRIVER
HD-35316-9
MAIN DRIVE GEAR REMOVER AND
INSTALLER SET
HD-35316-D
Main Drive Gear
1.
Split crankcases. See
2.
See
. From inside right crankcase, tap out seal
(3) at end of main drive gear (1). Discard seal.
3.
Obtain MAIN DRIVE GEAR REMOVER AND INSTALLER
SET (Part No. HD-35316-D). See
. Position
CROSS PLATE (Part No. B-45847) (1) on right crankcase
as shown. Position so roll pins (2) fit into crankcase mating
screw holes and bolt hole (3) is centered over main drive
gear (4).
2
3
4
1
5
sm01360
1. Main drive gear
2. Needle bearing (2)
3. Seal
4. O-ring
5. Retaining ring
Figure 5-65. Main Drive Gear Assembly (typical)
4.
See
. Insert 8 INCH BOLT (Part No. HD-35316-
4A) (2) through cross plate (1) and main drive gear (3).
5.
At outside of case, place WASHER (Part No. HD-35316-
7) (4), BEARING (5), FLAT WASHER (6) and NUT (7)
over end of bolt. Tighten nut until main drive gear is free.
1
4
3
2
sm01303
1. Cross plate
2. Roll pin (2)
3. Bolt hole
4. Main drive gear
Figure 5-66. Positioning Cross Plate (typical)
4
3
7
6
1
2
5
sm01304
1. Cross plate
2. 8 in bolt
3. Main drive gear
4. Washer
5. Bearing
6. Washer
7. Nut
Figure 5-67. Removing Main Drive Gear (typical)
5-40 2013 Sportster Service: Drive/Transmission
Main Drive Gear Ball Bearing
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTE
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
1.
See
. Remove and discard oil seal (10).
Remove and discard main drive gear bearing retaining
ring (9).
2.
XR 1200X:
Remove spacer (12) and O-ring (13).
3.
See
. Install driver components: From inside
crankcase, position bearing driver (2) over main drive gear
bearing.
a.
XL Models:
Use the BEARING DRIVER (Part
No. HD-35316-9).
b.
XR 1200X:
Use the BEARING DRIVER (Part No. HD-
35316-13).
4.
Insert 8 INCH BOLT (Part No. HD-35316-4A) (1) through
bearing driver and bearing.
5.
At outside of case, slide RECEIVER CUP (Part No. HD-
35316-11) (3) onto bolt and over bearing. Install the
bearing (4), flat washer (5) and nut (6) over end of bolt.
NOTE
Support bearing remover assembly as you remove bearing in
the following step. Entire assembly will fall out of crankcase
when bearing comes free.
6.
Tighten nut until main drive gear ball bearing is free.
7.
Discard main drive gear ball bearing.
2
3
1
4
5
6
sm01305a
1. 8 inch bolt
2. Bearing driver
3. Receiver cup
4. Bearing
5. Flat washer
6. Nut
Figure 5-68. Removing Main Drive Gear Bearing (typical)
DISASSEMBLY
TOOL NAME
PART NUMBER
BEARING RACE PULLER
HD-95637-46B
1.
See
. Remove retaining ring (11) from inboard
end of main drive gear (2). Discard retaining ring.
2.
See
. Drive out needle bearings (2) from inside
bore of main drive gear (1). Discard needle bearings. Do
not reuse bearings after removal from drive gear bore.
3.
Remove and discard O-ring (4).
NOTE
When the main drive gear is removed, a portion of the bearing
inner race remains attached to the main drive gear. Remove
this inner race before installing main drive gear.
2013 Sportster Service: Drive/Transmission 5-41
4.
See
. Attach BEARING RACE PULLER (Part
No. HD-95637-46B) (3) to inner race (2) on main drive
gear (1).
5.
Place main drive gear with bearing race puller assembly
onto press bed as shown in the photo.
NOTE
Provide a soft surface to catch the main drive gear when it falls
free in the next step.
6.
Press main drive gear out of inner bearing race. Discard
inner bearing race.
2
4
1
3
sm01306
1. Main drive gear
2. Inner bearing race (not visible in this photo)
3. Bearing race puller
4. Press ram
Figure 5-69. Removing Inner Bearing Race From Main Drive
Gear (typical)
ASSEMBLY
TOOL NAME
PART NUMBER
INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION
TOOL: XL MODELS
HD-47855
INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION
TOOL: XR 1200X
HD-48643
NOTE
The correct installed bearing depth is reached when the
installation tool bottoms on the gear.
1.
See
or
. Place main drive gear (4)
on press bed with gear end facing up.
2.
Place needle bearing (3) squarely into end of drive gear
with lettered side of bearing facing up. Always press on
lettered side of bearing to install. Insert the installation tool
(2) with end stamped "INNER" facing needle bearing.
a.
XL Models:
INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION TOOL: XL
MODELS (Part No. HD-47855)
b.
XR 1200X:
INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION TOOL: XR
1200X (Part No. HD-48643)
3.
Press in the inner bearing until the installation tool bottoms
on the main drive gear.
2
1
4
3
sm01307
1. Press ram
2. Needle bearing installation tool
3. Needle bearing
4. Main drive gear
Figure 5-70. Pressing Inner Needle Bearing Assembly into
Main Drive Gear: XL Models
1
2
4
3
sm05493
1. Press ram
2. Needle bearing installation tool
3. Needle bearing (not visible)
4. Main drive gear
Figure 5-71. Pressing Inner Needle Bearing Assembly into
Main Drive Gear: XR 1200X
4.
See
or
. Place main drive gear (4)
on press bed with gear end facing down.
5.
Place needle bearing (3) squarely into end of drive gear
with lettered side of bearing facing up. Always press on
5-42 2013 Sportster Service: Drive/Transmission
lettered side of bearing to install. Insert installation tool (2)
with end stamped "OUTER" facing needle bearing.
6.
Press in the outer needle bearing until the installation tool
bottoms on the main drive gear.
7.
See
. Install
new
retaining ring (11) in inboard
end of main drive gear (2).
2
1
4
3
sm01308
1. Press ram
2. Needle bearing installation tool
3. Needle bearing
4. Main drive gear
Figure 5-72. Pressing Outer Needle Bearing Assembly into
Main Drive Gear: XL Models
2
1
4
3
sm05494
1. Press ram
2. Needle bearing installation tool
3. Needle bearing (not visible)
4. Main drive gear
Figure 5-73. Pressing Outer Needle Bearing Assembly into
Main Drive Gear: XR 1200X
INSTALLATION
TOOL NAME
PART NUMBER
CROSS PLATE
B-45847
INSTALLER CUP
HD-35316-12
BEARING DRIVER
HD-35316-13
8 INCH BOLT
HD-35316-4A
WASHER
HD-35316-7
BEARING DRIVER
HD-35316-8
MAIN DRIVE GEAR REMOVER AND
INSTALLER SET
HD-35316-C
MAIN DRIVE GEAR SEAL INSTALLER
KIT
HD-47856
INSTALLER
HD-47856-1
PILOT
HD-47856-2
ADAPTER
HD-47856-4
LARGE NUT
HD-47856-5
Main Drive Gear Bearing: XL Models
1.
See
. Place CROSS PLATE (Part No. B-45847)
(1) on right crankcase as shown. Position cross plate so
that roll pins (2) fit into crankcase mating screw holes and
bolt hole (3) in cross plate is centered over crankcase
bearing bore (4).
2.
See
. Insert 8 INCH BOLT (Part No. HD-35316-
4A) (2) through cross plate (1) and main drive gear bearing
bore.
3.
Place main drive gear bearing (3), BEARING DRIVER
(Part No. HD-35316-8) (4), BEARING (5), FLAT WASHER
(6) and NUT (7) over end of bolt.
NOTE
Do not continue to tighten nut after bearing bottoms against
lip in crankcase bearing bore. Tightening nut too much can
break lip in bearing bore casting.
4.
Tighten nut until main drive gear bearing bottoms against
lip cast into crankcase bearing bore.
5.
Remove main drive gear bearing installer tool.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTE
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
6.
See
. At outside of case install
new
beveled
retaining ring (9) in groove inside bearing bore with
beveled side facing outside of case.
7.
Lubricate main drive gear bearing with SCREAMIN'
EAGLE ASSEMBLY LUBE.
2013 Sportster Service: Drive/Transmission 5-43
4
1
2
2
3
sm01309
1. Cross plate
2. Roll pin (2)
3. Bolt hole
4. Crankcase bearing bore
Figure 5-74. Positioning Cross Plate: XL Models
5
2
4
6
1
3
7
sm01310a
1. Cross plate
2. 8 inch bolt
3. Main drive gear bearing
4. Bearing driver
5. Bearing
6. Flat washer
7. Nut
Figure 5-75. Installing Main Drive Gear Bearing: XL Models
Main Drive Gear Bearing: XR 1200X
NOTE
Due to the design of the bearing, BEARING DRIVER (Part
No. HD-35316-13) and an arbor press must be used to press
the main drive gear bearing on all XR 1200X.
1.
See
. From the outside of the case, position
the main drive gear bearing (3) and bearing driver (2) over
bearing bore in crankcase.
2.
Press on main drive gear bearing driver until driver bottoms
against lip cast into crankcase bearing bore.
1
2
3
sm05744
1. Press ram
2. Bearing driver
3. Main drive gear bearing
Figure 5-76. Installing Main Drive Gear Bearing: XR 1200X
Main Drive Gear
1.
See
. Lubricate both main drive gear needle
bearing assemblies with SPECIAL PURPOSE GREASE.
2.
See
. Install
new
O-ring (3) into groove in main
drive gear (2). Lubricate O-ring with SCREAMIN' EAGLE
ASSEMBLY LUBE.
sm03400
Figure 5-77. Lubricating Main Drive Gear Needle Bearing
5-44 2013 Sportster Service: Drive/Transmission
11
1
3
4
6
14
13
12
9
10
8
7
5
2
1
sm01328
8.
1.
Countershaft bearing (closed end)
Needle bearing (2)
2.
9.
Main drive gear
Retaining ring
10.
3.
Oil seal
O-ring
4.
11.
Oil seal
Retaining ring
12.
5.
Spacer (XR 1200X)
Shifter drum bushing
6.
13.
Right crankcase
O-ring (XR 1200X)
14.
7.
Double roller bearing (XR 1200X)
Ball bearing (XL models)
Figure 5-78. Main Drive Gear and Bearing Assembly
3.
See
. Insert 8 INCH BOLT (Part No. HD-35316-
4A) (1) through WASHER (Part No. HD-35316-7) (2) and
main drive gear (3). From inside of case insert bolt with
washer and main drive gear through inner race of main
drive gear bearing.
4.
At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (4), BEARING (5), FLAT WASHER (6) and NUT
(7) over end of bolt. Tighten nut until main drive gear bot-
toms against main drive gear bearing.
5.
Remove
MAIN
DRIVE
GEAR
REMOVER
AND
INSTALLER SET (Part No. HD-35316-C) set.
6.
See
. Tap in
new
oil seal (4) at threaded end
of main drive gear to a depth of 0.060-0.030 in (1.524-
0.762 mm).
2013 Sportster Service: Drive/Transmission 5-45
3
6
5
4
1
2
7
sm01311b
1. 8 inch bolt
2. Washer
3. Main drive gear
4. Installer cup
5. Bearing
6. Flat washer
7. Nut
Figure 5-79. Installing Main Drive Gear (typical)
Main Drive Gear Seal
1.
XR 1200X:
See
. Install spacer (12) and
new
O-ring (13) onto main drive gear.
2.
Obtain MAIN DRIVE GEAR SEAL INSTALLER KIT (Part
No. HD-47856).
3.
See
. From outside of crankcase, install PILOT
(Part No. HD-47856-2) over end of main drive gear bearing
inner race.
4.
Coat lips of
new
main drive gear seal with SCREAMIN'
EAGLE ASSEMBLY LUBE.
5.
See
. Place seal over pilot and position seal
squarely in end of crankcase bore.
NOTE
ADAPTER (Part No. HD-47856-4) and main drive gear have
left-hand threads.
6.
See
. Thread ADAPTER (Part No. HD-47856-
4) onto end of main drive gear several turns. Do NOT
tighten on drive gear. Doing so could make it difficult to
remove adapter after seal has been installed.
sm01312a
Figure 5-80. Install Pilot (typical)
5-46 2013 Sportster Service: Drive/Transmission
sm01313a
Figure 5-81. Install Main Drive Gear Seal (typical, XL model
shown)
sm01314a
Figure 5-82. Install Adapter (typical, XL model shown)
7.
See
. Slide INSTALLER (Part No. HD-47856-
1) over adapter until cupped end of installer is flat against
seal.
8.
See
. Thread LARGE NUT (Part No. HD-
47856-5) onto end of adapter, until it tightens against
installer.
9.
See
. Place crow's foot wrench (1) with 1/2
inch drive breaker bar (2) on large nut. Place an adjustable
wrench (3) on flats of hex head cast into end of adapter.
10. Holding adjustable wrench, tighten large nut with crow's
foot wrench until outer face of seal is flush with outer edge
of crankcase bore.
NOTE
It is acceptable to recess seal to about 0.030 in (0.762 mm)
below outer edge of bore. Seal will be controlled by tool.
11. Remove nut, installer, adapter and pilot.
sm01315a
Figure 5-83. Place Installer over Adapter (typical, XL model
shown)
2013 Sportster Service: Drive/Transmission 5-47
sm01316a
Figure 5-84. Install Nut (typical, XL model shown)
2
1
3
sm01317a
1. Crowfoot wrench
2. 1/2 inch breaker bar
3. Adjustable wrench
Figure 5-85. Press Seal Into Crankcase (typical, XL model
shown)
5-48 2013 Sportster Service: Drive/Transmission
5.12
TRANSMISSION RIGHT CASE BEARINGS
REMOVAL
TOOL NAME
PART NUMBER
BUSHING AND BEARING PULLER
HD-95760-69A
1/2 INCH COLLET
HD-95765-69A
Split crankcases. See
Countershaft Needle Bearing
See
. From inside transmission case use a bearing
driver to remove countershaft bearing (1) from crankcase bore.
Shifter Drum Bushing
1.
See
. The shifter drum bushing (2) is a press
fit in the right crankcase half. Inspect the bushing against
the corresponding end of the shifter drum for proper fit
and wear.
2.
If bushing is to be replaced, use BUSHING AND BEARING
PULLER (Part No. HD-95760-69A) with 1/2 INCH COLLET
(Part No. HD-95765-69A) to remove bushing from crank-
case bore.
INSTALLATION
TOOL NAME
PART NUMBER
SNAP-ON BUSHING DRIVER SET
A-157C
Countershaft Needle Bearing
1.
Find a bearing driver 1-1/4 inch in diameter.
2.
See
. Position the open end of the countershaft
bearing (1) toward the bore in the outside of the case.
3.
Square the driver against the closed end of the bearing.
4.
Drive the bearing flush or no more than 0.030 in (0.762
mm) below the outside surface.
5.
Lubricate with SCREAMIN' EAGLE ASSEMBLY LUBE.
Shifter Drum Bushing
1.
See
. Using SNAP-ON BUSHING DRIVER
SET (Part No. A-157C) and the 1/2 inch adapter (Part No.
A157-8), install a
new
shifter drum bushing (2).
2.
Lubricate with SCREAMIN' EAGLE ASSEMBLY LUBE.
2
1
sm07172
1. Countershaft needle bearing
2. Shifter drum bushing
Figure 5-86. Transmission Right Case Bearings
2013 Sportster Service: Drive/Transmission 5-49
5.13
TRANSMISSION LEFT CASE BEARINGS
REMOVAL
TOOL NAME
PART NUMBER
SNAP-ON SNAP RING PLIERS
PR-36
Mainshaft and Countershaft Bearings
1.
Split crankcases. See
2.
Disassemble transmission. See
a.
Remove shifter forks and drum.
b.
Remove countershaft and mainshaft.
3.
Inspect the mainshaft and countershaft ball bearings for
pitting, scoring, discoloration or other damage.
4.
See
. If bearing replacement is required,
remove retaining rings (1, 2) using SNAP-ON SNAP RING
PLIERS (Part No. PR-36).
5.
Press out bearings (3, 4) from the inside of the crankcase.
Shifter Drum Bushing
1.
Inspect the shifter drum bushing for pitting, scoring, discol-
oration or excessive wear.
2.
If bushing requires replacement, press bushing out of
crankcase from primary side toward inside of case.
INSTALLATION
Mainshaft and Countershaft Bearings
1.
Place crankcase on press with inside surface of crankcase
downward.
2.
Lay bearing squarely over bore with printed side of bearing
upward.
3.
Place a driver (slightly smaller than outside diameter of
bearing) against outer race.
4.
Press bearing into bore until bearing bottoms against
shoulder.
5.
Install
new
retaining ring with beveled side facing away
from bearing.
Shift Drum Bushing
1.
Place crankcase on press with outside surface of crank-
case downward.
2.
See
. Lay bushing squarely over bore. Using
a pressing tool larger than OD of bushing, press bushing
into bore until tool contacts crankcase.
1
2
3
sm03388
1. Press bushing to contact shoulder in crankcase
half.
2. Shifter drum bushing.
3. Outside crankcase
Figure 5-87. Shifter Drum Bushing Assembly
3
4
1
2
sm01370
1. Retaining ring
2. Retaining ring
3. Mainshaft bearing
4. Countershaft bearing
Figure 5-88. Ball Bearing Assembly
5-50 2013 Sportster Service: Drive/Transmission
5.14
TRANSMISSION INSTALLATION
GENERAL
Before reinstalling transmission and reassembling crankcase
halves, perform any necessary engine overhaul procedures.
See
and
INSTALLATION
TOOL NAME
PART NUMBER
TRANSMISSION REMOVAL AND
INSTALLATION TOOL
B-43985
INSTALLER
B-43985-3
GUIDE
B-43985-4
CASE HOLDING FIXTURE
HD-46285-2
TORQUE VALUE
FASTENER
10.2-12.4 Nm
90-110
in-lbs
Gear detent assembly screw
1.
See
. Assemble detent spring (3) onto gear
detent assembly (2).
2.
Install detent assembly with spring into place in transmis-
sion cavity of right crankcase.
3.
Secure with screw (1). Tighten to 90-110
in-lbs
(10.2-12.4
Nm).
NOTE
Use the TRANSMISSION REMOVAL AND INSTALLATION
TOOL (Part No. B-43985) to install the countershaft.
4.
See
. Place transmission assembly (2) onto
CASE HOLDING FIXTURE (Part No. HD-46285-2) (3) on
press bed. Use support block(s) (4) if necessary.
5.
Screw the GUIDE (Part No. B-43985-4) (1) into end of
countershaft.
3
1
2
sm06783
1. Screw
2. Gear detent assembly
3. Detent spring
Figure 5-89. Gear Detent Assembly
3
1
4
2
sm01318a
1. Countershaft guide
2. Transmission
3. Transmission fixture
4. Support block(s)
Figure 5-90. Transmission on Fixture
6.
See
. Install left crankcase (3) over transmis-
sion assembly (4).
7.
Place the INSTALLER (Part No. B-43985-3) (2) over
mainshaft and countershaft bearings in crankcase.
8.
Position crankcase and transmission assemblies on press
with installer under press ram (1).
2013 Sportster Service: Drive/Transmission 5-51
5
4
3
1
2
sm01319a
1. Press ram
2. Installer
3. Crankcase
4. Transmission
5. Transmission fixture
Figure 5-91. Pressing Transmission into Left Crankcase
NOTE
Verify that the crankcase does not tilt when pressed onto
transmission assembly. Place press ram on the installer closer
to mainshaft to keep the crankcase level.
9.
Press crankcase onto transmission assembly until shafts
bottom out on bearings.
10. Remove left crankcase with transmission assembly from
press.
NOTE
When removing assembly from fixture, prevent 1st gear from
falling off shaft. Gear can be damaged if it strikes a hard sur-
face.
SHIFTER FORKS AND DRUM ASSEMBLY
NOTES
•
See
. Each shifter fork develops a wear pattern
with its mating parts. Install each shifter fork in its original
location.
•
Lubricate the shaft bore in each shifter fork with
SCREAMIN' EAGLE ASSEMBLY LUBE before assembly.
1.
Place 2nd/3rd gear shifter fork onto dog ring between
countershaft 2nd and 3rd gears.
2.
Install shifter drum into left case half with scribed line at
12 o'clock. This will place shifter drum in neutral position.
NOTE
See
. Install shifter fork shafts in the left case half
by lightly tapping on the end of the shaft with a brass or hard
plastic hammer until shaft is seated in bore.
3.
Place 1st gear shifter fork onto dog ring between counter-
shaft 1st and 4th gear gears. Install shifter fork shaft
through two installed shifter forks and into left crankcase
half.
4.
Install 4th/5th gear shifter fork onto sliding gear with dogs
located on mainshaft. Install remaining shifter fork shaft
through last installed shifter fork and into left crankcase
half.
NOTE
Seat shifter fork shafts in left crankcase half bore using light
taps with a brass hammer.
3
5
3
1
4
2
sm06844
1. Shifter drum
2. Mainshaft shifter fork (4th/5th)
3. Shifter fork shaft
4. Countershaft shifter fork (1st)
5. Coutnershaft shifter fork (2nd/3rd)
Figure 5-92. Shifter Forks, Drum and Shafts
sm01320a
Figure 5-93. Installing Shifter Fork Shafts
5-52 2013 Sportster Service: Drive/Transmission
ASSEMBLING CRANKCASES
TOOL NAME
PART NUMBER
GEAR DETENT ASSEMBLY AID
B-45520
CRANKSHAFT GUIDE TOOL
HD-42326-A
TORQUE VALUE
FASTENER
20.3-25.8 Nm
15-19 ft-lbs
Crankcase fastener
13.6-20.3 Nm
120-180
in-lbs
Neutral indicator switch
1.
See
. Retract detent assembly in right case
half and thread GEAR DETENT ASSEMBLY AID (Part
No. B-45520) into neutral switch hole until it has bottomed
in right case half.
2.
See
. Install flywheel assembly into right
crankcase half.
Do not rotate right crankcase half in engine stand such
that flywheel sprocket shaft is facing down. The flywheel
assembly can fall out, resulting in parts damage or mod-
erate injury. (00553b)
NOTE
Always place transmission in 1st gear when assembling
crankcases. Other gear selections could cause damage.
3.
Place transmission in 1st gear.
4.
See
. Assemble crankcase halves together.
a.
Slide CRANKSHAFT GUIDE TOOL (Part No. HD-
42326-A) onto flywheel sprocket shaft.
b.
Apply a thin coat of HARLEY-DAVIDSON GRAY
HIGH-PERFORMANCE SEALANT - GRAY to crank-
case joint faces.
c.
Lubricate main drive gear inner bearings with
SCREAMIN' EAGLE ASSEMBLY LUBE.
d.
Carefully fit crankcases together.
e.
Apply several drops of LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red)
to last few threads of crankcase fasteners.
f.
Install 11 long and four short from the left side and
two long from the right side.
g.
See
. In sequence, tighten to 15-19 ft-lbs
(20.3-25.8 Nm).
5.
Remove GEAR DETENT ASSEMBLY AID and install
neutral indicator switch and flat washer. Tighten to 120-
180
in-lbs
(13.6-20.3 Nm).
1
2
sm01372
1. Detent assembly
2. Detent assembly aid
Figure 5-94. Using Gear Detent Assembly Aid (Part No.
B-45520)
sm06549
Figure 5-95. Installing Flywheel Assembly In Right
Crankcase
2013 Sportster Service: Drive/Transmission 5-53
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