Harley Davidson 2013 Sportster Models. Service Manual — page 40
INSTALLATION
TOOL NAME
PART NUMBER
SPORTSTER 5-SPEED SPROCKET
LOCKING LINK
HD-38362
PRIMARY DRIVE LOCKING TOOL
HD-46283
TORQUE VALUE
FASTENER
210.0-224.0
Nm
155-165 ft-lbs
Engine sprocket bolt: XR
1200X
67.8-81.3 Nm
50-60 ft-lbs
Transmission mainshaft nut:
XR 1200X
1.
See
. Remove retaining ring (12). Remove
adjusting screw assembly (13, 14, 15, 16) from pressure
plate (17) to allow installation of the transmission mainshaft
nut and washer.
NOTE
Prior to installing engine sprocket bolt and transmission main-
shaft nut, thoroughly clean threads of engine sprocket shaft,
transmission mainshaft and mainshaft nut to remove any oil
that might contaminate and interfere with locking agent.
2.
Thoroughly clean threads of engine sprocket shaft, trans-
mission mainshaft and mainshaft nut to remove any oil.
NOTES
•
See
. Do not position the sprocket locking link
(1) too close to the shifter shaft (2). The sprocket locking
can damage the shifter shaft and/or engine crankcase.
•
Japan models use PRIMARY DRIVE LOCKING TOOL
(Part No. HD-46283).
3.
See
Install
SPORTSTER
5-SPEED
SPROCKET LOCKING LINK (Part No. HD-38362) (1).
4.
Install
new
engine sprocket bolt. Tighten to 155-165 ft-lbs
(210.0-224.0 Nm).
NOTE
See
. Washer (2) must be installed with the word
"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.
5.
Install mainshaft nut.
a.
See
. Apply two or three drops of LOCTITE
262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red) onto threads of transmission main-
shaft.
b.
Install spring washer (2) and mainshaft nut (1) (left-
hand threads) on transmission mainshaft.
c.
Tighten to 50-60 ft-lbs (67.8-81.3 Nm).
6.
Remove the sprocket locking link.
7.
See
. Install adjusting screw assembly in
pressure plate with two tabs on perimeter of release plate
matched to recesses in pressure plate. Secure with a
new
retaining ring.
8.
Install primary cover using
new
gasket. See
.
9.
Adjust primary chain and clutch. See
and
10. Fill transmission. See
11. Connect battery and close left side cover. See
.
2
1
sm06563
1. Sprocket locking link
2. Shifter shaft
Figure 5-33. Tighten Engine Sprocket Bolt
1
3
2
sm00290
1. Mainshaft nut
2. Washer
3. Clutch hub
Figure 5-34. Mainshaft Nut and Washer
5-22 2013 Sportster Service: Drive/Transmission
2
3
1
3
sm00288a
1. Adjusting screw assembly
2. Retaining ring
3. Tab recesses
Figure 5-35. Clutch Adjusting Screw Assembly and
Retaining Ring
2013 Sportster Service: Drive/Transmission 5-23
5.6
DRIVE BELT
DRIVE BELT HANDLING
See
.
•
Do not exceed 5 in (127 mm) forward bend (1).
•
Do not exceed 10 in (254 mm) reverse bend (2).
•
Do not twist (3).
•
Do not crimp, pinch or kink (4).
•
Do not pry (5).
4
3
5
1
2
sm02440a
Figure 5-36. Drive Belt Handling
DRIVE BELT: XL MODELS
TORQUE VALUE
FASTENER
40.7-44.8 Nm
30-33 ft-lbs
Exhaust pipe clamp bracket
fastener: XL Models
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
Removal
1.
Remove
mufflers
and
rear
exhaust
pipe.
See
4.13 EXHAUST SYSTEM: XL MODELS
.
2.
Mid-Mount
Controls:
Remove
right
side
rider
footrest/brake pedal and mounting bracket assembly. See
2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CON-
TROLS
.
3.
See
. Remove screw (6), washer (5) and
exhaust pipe clamp bracket (4).
4.
Remove two screws (2, 3).
5.
See
. Remove E-clip (1). Discard E-clip.
6.
Loosen rear axle nut (4).
7.
Turn the axle adjuster nut (2) on each side of rear fork an
equal number of turns counterclockwise to decrease belt
tension.
8.
Remove right lower shock absorber screw, washer and
locknut. See
.
9.
Remove the belt guard. See
DEBRIS DEFLECTOR, Belt Guard: XL Models
.
10. Remove the debris deflector. See
AND DEBRIS DEFLECTOR, Debris Deflector: XL Models
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
11. See
. Remove belt.
3
2
6
5
4
1
sm01356
1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw
Figure 5-37. Sprocket Cover: XL Models
5-24 2013 Sportster Service: Drive/Transmission
2
1
3
6
5
4
sm03591d
1. E-clip
2. Axle adjuster nut (2)
3. Axle adjuster (2)
4. Axle nut
5. Washer
6. Protective cap (2)
Figure 5-38. Drive Belt Adjustment: XL Models
sm07540
Figure 5-39. Drive Belt Removal: XL Models
Installation
1.
Install belt onto sprockets.
2.
Install the front of belt guard. See
DEBRIS DEFLECTOR, Belt Guard: XL Models
.
3.
Install the debris deflector. See
DEBRIS DEFLECTOR, Debris Deflector: XL Models
.
4.
Install right lower shock absorber bolt, washer and locknut.
See
2.24 SHOCK ABSORBERS, Installation
NOTE
See
. Short screw (2) goes in bottom hole. Long
screw (3) goes in top hole. Do not tighten screws.
5.
Install sprocket cover (1). Secure with two screws.
6.
Install exhaust pipe clamp bracket (4), washer (5) and
screw (6).
7.
Tighten:
a.
Exhaust pipe clamp bracket fastener 30-33 ft-lbs
(40.7-44.8 Nm)
b.
Sprocket cover fasteners 80-120
in-lbs
(9.0-13.6 Nm)
8.
Mid-Mount Controls:
Install right side rider footrest/brake
pedal and mounting bracket assembly. See
FOOT CONTROLS: XL MID-MOUNT CONTROLS
.
9.
Install rear exhaust pipe and mufflers. See
10. Adjust belt tension. See
SPROCKETS, Drive Belt Deflection
11. Check wheel alignment. See
12. See
. Tighten rear axle nut (4) to 95-105 ft-lbs
(129-142 Nm).
13. Install
new
E-clip (1).
IDLER PULLEY: XR 1200X
TORQUE VALUE
FASTENER
95-109 Nm
70-80 ft-lbs
Idler pulley fastener: XR
1200X
44.7-47.5 Nm
33-35 ft-lbs
Idler pulley bracket flanged
nut: XR 1200X
40.7-44.8 Nm
30-33 ft-lbs
Sprocket cover, rear screw
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
Removal
1.
See
. Remove sprocket cover (1).
NOTE
It is not necessary to remove the drive belt completely.
2.
Release tension from drive belt and slide belt off drive
sprocket (5). See
5.6 DRIVE BELT, Drive Belt: XL Models
NOTE
If exhaust system interference prevents removal, loosen all
exhaust system mount fasteners and flange nuts. Pull exhaust
system away from engine to allow room to remove idler
assembly.
3.
Remove nuts (3) and washers (4). Remove idler pulley
and bracket assembly from vehicle.
4.
Spin and check idler pulley (7) for bearing wear. See
1.12 DRIVE BELT AND SPROCKETS, Inspection
NOTE
The idler pulley bearings can not be replaced separately.
5.
If idler pulley needs replacement, remove fastener (8) and
bushings (2). Discard idler pulley and replace with
new
idler pulley (7).
2013 Sportster Service: Drive/Transmission 5-25
1
8
2
3
4
6
5
7
sm05541
1. Sprocket cover
2. Bushing (2)
3. Flanged nut (2)
4. Washer (2)
5. Drive sprocket
6. Idler pulley bracket
7. Idler pulley
8. Fastener
Figure 5-40. Drive Belt Idler: XR 1200X
Installation
1.
See
. Install
new
or existing idler pulley (7), if
removed. Tighten fastener (8) to 70-80 ft-lbs (95-109 Nm).
2.
Install idler pulley and bracket assembly. Install washers
(4) and flanged nuts (3). Tighten to 33-35 ft-lbs (44.7-47.5
Nm).
3.
Install drive belt and adjust belt tension and wheel align-
ment. See
.
4.
Install sprocket cover:
a.
Tighten rear (larger) screw to 30-33 ft-lbs (40.7-44.8
Nm).
b.
Tighten forward and lower (smaller) screws to 80-120
in-lbs
(9.0-13.6 Nm).
5.
If loosened, align. Tighten exhaust system components.
See
.
DRIVE BELT: XR 1200X
TORQUE VALUE
FASTENER
40.7-44.8 Nm
30-33 ft-lbs
Sprocket cover, rear screw
9.0-13.6 Nm
80-120
in-lbs
Sprocket cover, forward and
lower screws
129-142 Nm
95-105 ft-lbs
Axle, rear, nut
Removal
1.
Remove exhaust system. See
2.
See
. Remove screws (2, 3, 4). Remove
sprocket cover (1).
3.
See
. Remove E-clip. Discard E-clip (1).
4.
Loosen rear axle nut (4).
5.
Turn the axle adjuster nut (2) on each side of rear fork an
equal number of turns counterclockwise to release belt
tension.
6.
Remove right lower shock absorber screw, washer and
locknut. See
.
7.
Remove belt guard. See
DEFLECTOR, Belt Guard: XR 1200X
.
8.
Remove debris deflector. See
DEBRIS DEFLECTOR, Debris Deflector: XR 1200X
.
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
9.
See
. Remove belt.
1
2
3
4
sm05328
1. Sprocket cover
2. Rear screw and washer
3. Front screw
4. Lower screw
Figure 5-41. Sprocket Cover: XR 1200X
5-26 2013 Sportster Service: Drive/Transmission
3
5
1
6
4
2
sm07549
1. E-clip
2. Axle adjuster nut (2)
3. Axle adjuster (2)
4. Axle nut
5. Washer
6. Protective cap (2)
Figure 5-42. Drive Belt Adjustment: XR 1200X
sm07548
Figure 5-43. Drive Belt Removal: XR 1200X
Installation
1.
Install belt onto sprockets.
2.
Install belt guard. See
DEFLECTOR, Belt Guard: XR 1200X
.
3.
Install debris deflector. See
DEBRIS DEFLECTOR, Debris Deflector: XR 1200X
.
4.
Install right lower shock absorber bolt, washer and locknut.
See
2.24 SHOCK ABSORBERS, Installation
.
NOTE
See
. Long screw (3) goes in top hole. Short screw
(4) goes in bottom hole.
5.
Install sprocket cover (1).
a.
Tighten screw (2) to 30-33 ft-lbs (40.7-44.8 Nm).
b.
Tighten screws (3, 4) to 80-120
in-lbs
(9.0-13.6 Nm).
6.
Install exhaust system. See
7.
Adjust belt tension. See
SPROCKETS, Drive Belt Deflection
8.
Check rear wheel alignment. See
9.
See
. Tighten rear axle nut (4) to 95-105 ft-lbs
(129-142 Nm). Install
new
E-clip (1).
2013 Sportster Service: Drive/Transmission 5-27
5.7
TRANSMISSION POWER FLOW
GENERAL
See
. The transmission is a five-speed constant-
mesh type housed in an extension of the crankcase. The
transmission permits the rider to vary the ratio of engine speed-
to-rear driving wheel speed in order to meet the varying condi-
tions of operation.
The transmission is foot-operated by the gear shifter lever,
which transmits the force through a gear shifter shaft. The
shifter shaft actuates a pawl and a shifter fork drum. The shifter
fork drum moves shifter forks. The shifter forks slide a series
of shifter dogs into and out of mesh with the other gears.
5-28 2013 Sportster Service: Drive/Transmission
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
2
3
4
1
5
3
{
1
2
N
1
2
4
5
3
4
5
6
7
sm03353
5.
1.
Power flow
Mainshaft
2.
6.
Countershaft
Moves in
7.
3.
Moves out
Countershaft gears
4. Sliding member
Figure 5-44. Transmission Power Flow
2013 Sportster Service: Drive/Transmission 5-29
5.8
CASE DISASSEMBLY FOR TRANSMISSION
REMOVAL
GENERAL
The rear compartment of the left and right crankcase halves
form the transmission case. Servicing of transmission compon-
ents requires removing the engine and disassembling (splitting)
the crankcase.
ENGINE REMOVAL AND DISASSEMBLY
TOOL NAME
PART NUMBER
ENGINE SUPPORT CRADLE
HD-42310-45
1.
Remove engine from chassis. See
2.
Support engine using ENGINE SUPPORT CRADLE (Part
No. HD-42310-45).
3.
Disassemble top end. See
4.
Remove primary cover, clutch assembly, primary chain
and engine sprocket. See
or
.
5.
Disassemble gearcase. See
.
6.
Remove transmission sprocket.
7.
See
. Place transmission in 1st gear. Remove
countershaft retaining screw (1).
8.
Place transmission in neutral. See
. Unplug
neutral switch connector [131] (2) by pulling connector
straight off neutral switch (1). Remove neutral switch and
flat washer.
9.
See
. Verify shifter drum detent is visible in
neutral switch hole indicating that transmission is in
neutral.
2
1
sm03354
1. Countershaft retaining screw
2. Shifter shaft assembly
Figure 5-45. Countershaft Retaining Screw
1
2
sm03355
1. Neutral indicator switch
2. Neutral switch connector
Figure 5-46. Neutral Switch and Connector
sm03356
Figure 5-47. Shifter Drum Neutral Detent
10. See
and
. Compress the ratchet
arms (item 2,
) in order to clear the shifter
drum, and remove shifter shaft assembly from left crank-
case half.
11. Remove starter. See
.
12. See
. With transmission still in neutral, scribe
a line on the end of the shifter drum at the 12 o'clock
position for later reference.
5-30 2013 Sportster Service: Drive/Transmission
2
3
2
1
sm03357a
1. Shifter shaft
2. Ratchet arms
3. Return spring
Figure 5-48. Shifter Shaft Assembly
sm01323a
Figure 5-49. Removing Shifter Shaft Assembly
sm03359
Figure 5-50. Scribed Line on Shifter Drum at 12 o'clock
1
2
1
1
1
1
1
1
1
4
4
1
1
3
3
3
3
sm03405a
1. Long fastener: left side
2. XR 1200X: double-headed long fastener
3. Short fastener: left side
4. Long fastener: right side
Figure 5-51. Crankcase Fasteners
NOTE
Crankcase assembly has 17 fasteners: 15 inserted from left
side and two inserted from right side. Make certain all fasteners
have been removed before attempting to separate crankcase
halves.
13. See
. Remove 15 crankcase fasteners (11 long
and four short) from left side of crankcase assembly.
Remove two fasteners from right side of crankcase
assembly.
2013 Sportster Service: Drive/Transmission 5-31
14. Tap crankcase gently with rawhide mallet to loosen and
separate the halves. See
. Remove left
crankcase assembly with transmission.
NOTE
Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.
15. See
. Remove flywheel assembly from right
crankcase half.
16. See
. Remove screw (1), gear detent assembly
(2) and detent spring (3) from inside transmission cavity
of right crankcase.
sm06548
Figure 5-52. Separating Crankcase Halves
sm06549
Figure 5-53. Removing Flywheel Assembly From Right
Crankcase Half
3
1
2
sm06783
1. Screw
2. Gear detent assembly
3. Detent spring
Figure 5-54. Gear Detent Assembly
5-32 2013 Sportster Service: Drive/Transmission
5.9
TRANSMISSION REMOVAL AND DISASSEMBLY
TRANSMISSION REMOVAL FROM LEFT
CRANKCASE
TOOL NAME
PART NUMBER
REMOVER
B-43895-1
TRANSMISSION REMOVAL AND
INSTALLATION TOOL
B-43985
NOTE
See
. Shifter design allows for one common part
number for both countershaft shifter forks (4, 5). As the trans-
mission runs, each shifter fork develops a certain wear pattern
with its mating parts. Install shifter forks in original locations.
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 5-55. Shifter Forks, Drum and Shafts
1.
See
. Remove shifter fork shafts by inserting
a small flat punch in the slots and tapping on the end of
each shaft until it falls free.
NOTE
Carefully tap on alternate sides of the shaft using the provided
slots.
2.
See
. Remove shifter drum (1) and shifter forks
(2). Mark each shifter fork as it is removed, so it can be
reinstalled in the same location.
sm03369b
Figure 5-56. Slots For Removing Shifter Fork Shafts
2
3
1
4
2
5
sm03370a
1. Shifter drum
2. Shifter fork (3)
3. Mainshaft
4. Mainshaft 2nd gear
5. Countershaft
Figure 5-57. Transmission Assembly
2013 Sportster Service: Drive/Transmission 5-33
3
2
1
4
5
6
sm03372
1. Press ram
2. Transmission remover
3. Crankcase
4. Transmission assembly (countershaft visible)
5. Parallel support (2)
6. Press bed
Figure 5-58. Pressing Transmission From Left Crankcase
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 the TRANSMISSION REMOVAL AND INSTALLATION
TOOL (Part No. B-43985) to remove the transmission.
3.
See
. Remove left crankcase half and transmis-
sion assembly (4) from engine stand.
a.
Place crankcase half (3) and transmission assembly
(4) on arbor press (1) and support transmission
assembly on parallel supports (5).
b.
Press transmission assembly using REMOVER (Part
No. B-43895-1) (2) to remove transmission from
crankcase half.
c.
Remove crankcase from press.
MAINSHAFT/COUNTERSHAFT
NOTES
•
Transmission operation creates a specific wear pattern
on the parts. Always install parts in their original locations
and orientations.
•
See
. As each component is removed, place
it on a clean surface in the exact order of removal.
1
2
1
2
sm03373a
1. Mainshaft
2. Countershaft
Figure 5-59. Transmission Parts Identification
MAINSHAFT DISASSEMBLY
TOOL NAME
PART NUMBER
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586-A
NOTES
•
Mainshaft 2nd and 3rd gears are integral to the shaft.
•
Mainshaft 1st gear is directional. Mark gear when removed
for correct installation.
•
Press transmission assembly out of left crankcase half to
service mainshaft and countershaft.
•
All thrust washers are one common part number. This
transmission requires no shimming.
•
Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.
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)
1.
See
. Remove 1st gear (1).
2.
Use TRANSMISSION SHAFT RETAINING RING PLIERS
(Part No. J-5586-A) to expand and remove retaining ring
(2). Discard retaining ring.
3.
Slide thrust washer (3) off end of mainshaft.
4.
Remove 4th gear (4) and split bearing (5). Discard bearing.
5-34 2013 Sportster Service: Drive/Transmission
3
2
1
4
5
6
7
8
sm03375
5.
1.
Split bearing
Mainshaft 1st gear
2.
6.
Retaining ring
Mainshaft
7.
3.
Mainshaft 3rd gear (integral to shaft)
Thrust washer
4.
8.
Mainshaft 4th gear
Mainshaft 2nd gear (integral to shaft)
Figure 5-60. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly
Cleaning and Inspection
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts in cleaning solvent. Blow dry with com-
pressed air.
2.
Check gear teeth for damage. Replace if necessary.
3.
Inspect the engaging dogs on the gears. Replace if
necessary.
COUNTERSHAFT DISASSEMBLY
TOOL NAME
PART NUMBER
RETAINING RING PLIERS
J-5586-A
NOTES
•
Countershaft 5th gear is integral to the shaft.
•
Once the transmission assembly has been pressed out
of the left crankcase half, the mainshaft and countershaft
assemblies can be serviced separately.
•
All thrust washers are one common part number. This
transmission requires no shimming.
•
Use correct retaining ring pliers with correct tips. Verify
that tips are not excessively worn or damaged.
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)
1.
See
. Remove spacer (19) and 2nd gear (18)
from the end of the of the countershaft (2). Remove and
discard split bearing (17).
2.
Remove spacer (16).
NOTE
When removing the dog ring (15), it is important to mark the
direction of the ring on the shaft as parts establish wear pat-
terns.
3.
Remove dog ring (15).
4.
Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and remove retaining ring (14). Discard retaining
ring.
5.
Remove thrust washer (13), 3rd gear (12), and split
bearing (11). Discard bearing.
6.
Remove thrust washer (10).
7.
Expand, remove and discard retaining ring (9).
8.
Remove 4th gear (8) and dog ring (7).
9.
Expand, remove and discard retaining ring (6).
10. Remove thrust washer (5), 1st gear (4) and split bearing
(3). Discard bearing.
2013 Sportster Service: Drive/Transmission 5-35
Cleaning and Inspection
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Clean all parts (except bearings) in cleaning solvent and
blow dry with compressed air.
2.
Check gear teeth for damage. Replace if necessary.
3.
Inspect the engaging dogs on the gears. Replace if
necessary.
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 5-61. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
5-36 2013 Sportster Service: Drive/Transmission
5.10
TRANSMISSION ASSEMBLY
MAINSHAFT ASSEMBLY
TOOL NAME
PART NUMBER
RETAINING RING PLIERS
J-5586-A
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)
NOTES
•
Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.
•
Lubricate spit bearings and internal bores of gears with
SCREAMIN' EAGLE ASSEMBLY LUBE prior to assembly.
1.
See
. Install
new
split bearing (5) in 4th gear
position on mainshaft.
2.
Install 4th gear (4) and thrust washer (3).
3.
Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install new retaining ring (2).
4.
Install 1st gear (1).
3
2
1
4
5
6
7
8
sm03375
5.
1.
Split bearing
Mainshaft 1st gear
2.
6.
Retaining ring
Mainshaft
7.
3.
Mainshaft 3rd gear (integral to shaft)
Thrust washer
4.
8.
Mainshaft 4th gear
Mainshaft 2nd gear (integral to shaft)
Figure 5-62. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly
COUNTERSHAFT ASSEMBLY
TOOL NAME
PART NUMBER
RETAINING RING PLIERS
J-5586-A
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)
NOTES
•
Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.
•
During assembly, the split bearings and the internal bores
of the gears must be lubricated with SCREAMIN' EAGLE
ASSEMBLY LUBE prior to assembly. Leaving these parts
dry could accelerate wear at start-up.
1.
See
. Install
new
split bearing (3) in 1st gear
position on mainshaft.
2.
Install 1st gear (4) and thrust washer (5).
3.
Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install
new
retaining ring (6).
4.
Install dog ring (7) onto 4th gear (8). Now install dog ring
and gear assembly onto countershaft.
5.
Expand and install
new
retaining ring (9).
6.
Install thrust washer (10).
7.
Install
new
split bearing (11) in 3rd gear position on
mainshaft.
8.
Install 3rd gear (12) and thrust washer (13).
2013 Sportster Service: Drive/Transmission 5-37
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