Harley Davidson 2011 Touring Models. Service Manual — page 23
3
2
1
4
2
3
4
1
sm02386a
Figure 3-86. Rocker Arm Bolt Sequence (late production
shown)
6.
Complete installation of the push rod covers.
a.
Verify that the O-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.
b.
Insert the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.
c.
Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.
NOTE
For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.
d.
See
. While simultaneously depressing
spring cap with tip of screwdriver, use forefinger to
slide bottom edge of spring cap retainer down shaft
towards tip of screwdriver blade. As spring cap
reaches its full length of travel, spring cap retainer
should be in approximate position against upper push
rod cover.
e.
Verify that spring cap retainer is seated tightly against
upper push rod cover.
sm02347
Figure 3-87. Install Spring Cap Retainers
BREATHER AND ROCKER COVER
TOOL NAME
PART NUMBER
"DOG BONE" TORQUE ADAPTER
SNAP-ON FRDH141
NOTE
For
breather
assembly
service
procedures,
see
.
1.
To secure breather assembly, tighten two screws to 120-
156
in-lbs
(13.6-17.6 Nm).
NOTE
If the engine was left in the chassis for service, final tighten
the three rocker cover bolts on the left side of the rear cylinder
using a 3/8 in. drive torque wrench with a 7/16 in. flank drive
"DOG BONE" TORQUE ADAPTER (Part No. Snap-on
FRDH141). Failure to properly use this combination will over-
tighten the bolts causing distortion of the rocker cover.
2.
Apply a drop of LOCTITE THREADLOCKER 243 (blue)
to threads of rocker cover screws.
3.
See
. Install rocker cover and a
new
rocker
cover gasket. Tighten screws following the sequence
shown to 15-18 ft-lbs (20.3-24.4 Nm).
2011 Touring Service: Engine 3-73
4.
Complete motorcycle assembly.
a.
If engine was left in the chassis for service, see
3.15 ASSEMBLING MOTORCYCLE AFTER SER-
VICE
b.
If
engine
was
removed
for
service,
see
3.17 INSTALLING ENGINE IN CHASSIS
6
2
4
3
1
5
4
2
6
5
1
3
sm02326
1. Short bolt, 1.0 in. (25.4 mm)
2. Long bolt, 1.75 in. (44.5 mm)
3. Short bolt, 1.0 in. (25.4 mm)
4. Long bolt, 1.75 in. (44.5 mm)
5. Short bolt, 1.0 in. (25.4 mm)
6. Long bolt, 1.75 in. (44.5 mm)
Figure 3-88. Rocker Cover Bolts Torque Sequence
3-74 2011 Touring Service: Engine
3.26
CAM COMPARTMENT AND COMPONENTS
CAM SUPPORT PLATE AND COVER
REMOVAL
TOOL NAME
PART NUMBER
SCREAMIN' EAGLE MAGNETIC
LIFTER HOLDERS
93979-10
CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL
HD-47941
Prepare Engine
NOTE
The following steps outline removal with the rest of the engine
intact. If performing a complete engine overhaul, perform all
steps under
3.18 TOP END OVERHAUL: DISASSEMBLY
1.
Remove breather assembly, rocker arm support plate,
push rods and push rod covers. Do not remove lifters. See
appropriate topics under
2.
See
. Support lifters using SCREAMIN' EAGLE
MAGNETIC LIFTER HOLDERS (Part No. 93979-10).
3.
See
. Remove the socket head screws to
release the cam cover. Remove and discard the cam cover
gasket.
NOTE
Cam cover screws are 1/4 x 1-1/4 in. while the cam support
plate, lifter cover and crankshaft position sensor screws are
1/4 x 1 in. The shorter screws are interchangeable. Use care
to keep the two lengths separate to be sure of using the correct
length during assembly.
6
1
5
8
7
4
9
10
2
3
sm02183
Figure 3-89. Cam Cover Screws
sm02510a
Figure 3-90. Screamin' Eagle Magnetic Lifter Holder
Cam Chain and Sprockets Removal
1.
See
. Using a colored marker, mark one of the
links (1) of the primary cam chain to identify the visible
side. Maintaining the original direction of rotation during
assembly may prolong service life.
NOTE
Use a piece of wire in retention hole (6) to keep cam chain
tensioner components assembled.
2.
Remove primary cam chain tensioner fasteners (4) and
primary cam chain tensioner (3).
NOTE
Be sure side of tool labeled "crank side" faces crankshaft
sprocket.
3.
See
. Install CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL (Part No. HD-47941)
between cam sprocket (2) and crank sprocket (5).
Be sure to follow manufacturer's instructions when using
propane
torches.
Failure
to
follow
manufacturer's
instructions can cause a fire, which could result in death
or serious injury. (00465c)
•
Avoid directing heat toward any fuel system com-
ponent. Extreme heat can cause fuel ignition/explosion
resulting in death or serious injury.
•
Avoid directing heat toward any electrical system
component.
NOTES
•
Only use approved methods for removing rear cam bolt.
Other methods of removal, such as the use of a large
2011 Touring Service: Engine 3-75
breaker bar, may result in damage to chain drive and other
components.
•
If necessary, soften LOCTITE by using heat from a small
propane torch. Apply flame evenly around bolt in a circular
motion, but do not allow bolt to turn blue.
4.
Remove the rear cam sprocket bolt and flat washer (1)
from the rear cam sprocket (2).
5.
Remove the crank sprocket bolt and flat washer (4) from
the crank sprocket (5).
6.
Remove camshaft locking tool.
7.
Use a small pry bar between rear cam sprocket and cam
support plate to carefully ease off rear cam sprocket until
loose on camshaft.
8.
Use a small pry bar to ease off crank sprocket. Remove
both sprockets and primary cam chain.
5
3
6
1
2
4
sm02399
1. Link
2. Rear cam sprocket
3. Primary cam chain tensioner
4. Primary cam chain tensioner fasteners
5. Crank sprocket
6. Retention hole
Figure 3-91. Cam Support Plate Assembly
4
5
3
2
1
sm02401
1. Rear cam sprocket bolt (large) and flat washer
2. Rear cam sprocket
3. Camshaft locking tool
4. Crank sprocket bolt (small) and flat washer
5. Crank sprocket
Figure 3-92. Cam Support Plate Assembly
Cam Support Plate Removal
1.
See
. Following the sequence shown, remove
four socket head screws.
2.
See
. Following the sequence shown, remove
six socket head screws to release the cam support plate
from the crankcase.
3.
See
. Use a small pry bar between the cam
support plate and crankcase flange in areas adjacent to
the ring dowels (2, 3) to work cam support plate and
camshafts from end of crankshaft.
3-76 2011 Touring Service: Engine
4
2
1
3
sm02185
Figure 3-93. Oil Pump Torque Sequence
4
2
6
3
5
1
sm02404
Figure 3-94. Cam Support Plate Torque Sequence
2
1
3
sm02407
1. Right crankcase half
2. Forward ring dowel
3. Rear ring dowel
Figure 3-95. Ring Dowels
CAM SUPPORT PLATE CLEANING AND
INSPECTION
Oil Pressure Valve
Inspect oil pressure valve. See
AND COMPONENTS, Oil Pressure Relief Valve
.
Cam Support Plate
1.
Measure the diameters of the camshaft bores and crank-
shaft bore. See
3.3 SERVICE WEAR LIMITS, General
.
2.
Measure flatness of support plate. See
3.
Inspect gerotor area for excessive wear or deep grooves.
4.
Verify that all oil holes are clean and open.
NOTE
Exercise caution to avoid enlarging the oil holes or oil pressure
will be adversely affected.
CAMSHAFTS
TOOL NAME
PART NUMBER
CAMSHAFT ASSEMBLY TOOL
HD-47956
Removal
1.
See
. Remove screws (4) and remove sec-
ondary cam chain tensioner (3).
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)
2011 Touring Service: Engine 3-77
Countershaft
NOTES
•
If removing countershaft without removing the mainshaft,
hold countershaft 3rd and 4th gear shift dog up while
pressing countershaft out of side door bearings.
•
Do not press directly on the end of the countershaft. Place
a spacer such as a washer between the end of the coun-
tershaft and the press ram.
1.
Press countershaft out of side door bearings.
2.
See Removing Side Door Bearings on the following page
for side door bearing replacement.
3.
See
. Remove washer (1), countershaft 1st
gear (2) and bearing.
NOTE
See
. Note the direction that the 2nd gear locking
ring is installed.
4.
Remove countershaft 2nd gear lock ring.
5.
See
. Remove securing segments (1). Remove
dog ring (3), guiding hub (2), countershaft 2nd gear (4)
and bearing.
2
1
sm03020a
1. Washer
2. Countershaft 1st gear
Figure 6-17. Countershaft 1st Gear
sm03021
Figure 6-18. Lock Ring
1
4
1
2
3
sm03022
1. Securing segment
2. Guiding hub
3. Dog ring
4. Countershaft 2nd gear
Figure 6-19. Securing Segment
NOTE
See
. Note the direction that the 3rd gear locking
ring is installed.
6.
Remove countershaft 3rd gear lock ring.
7.
See
. Remove securing segments (1), internal
spline washer (2), countershaft 3rd gear (3) and bearing.
NOTE
See
. Note the direction that the 4th gear locking
ring is installed.
8.
Remove 4th gear lock ring (1), securing segments, dog
ring (3), guiding hub (2), and countershaft 4th gear (4) and
bearing.
2011 Touring Service: Transmission 6-13
NOTE
As countershaft 5th gear and 6th gear are an integral part of
the shaft, damage to either gear requires countershaft
replacement.
sm03023
Figure 6-20. Third Gear Lock Ring
1
2
3
1
sm03024
1. Securing segment
2. Internal spline washer
3. Countershaft 3rd gear
Figure 6-21. Countershaft Third Gear
4
2
3
1
sm03025a
1. 4th gear lock ring
2. Guiding hub
3. Dog ring
4. Countershaft 4th gear
Figure 6-22. Countershaft Assembly
Removing Side Door Bearings
NOTE
Always replace side door bearing if the shaft is pressed out.
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 the retaining rings (1).
2.
Press the bearings out of the side door.
3
2
1
sm05071
1. Retaining ring (2)
2. Bearing (2)
3. Side door
Figure 6-23. Side Door Bearings
6-14 2011 Touring Service: Transmission
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 with solvent. Blow parts dry with low pres-
sure compressed air.
2.
Check gear teeth for damage. If gears are pitted, scored,
rounded, cracked or chipped, they should be replaced.
3.
Inspect the engaging dogs and pockets on the dog rings.
Replace the dog rings if dogs and/or pockets are rounded,
battered or chipped.
4.
Inspect guiding hubs. Replace guiding hubs if splines are
rounded, battered or chipped.
5.
Inspect shift fork shafts. Replace if bent or damaged.
6.
Inspect shift forks for wear or signs of overheating.
Replace a shift fork if it is excessively worn or shows signs
of overheating.
7.
See
. Using a small carpenter's square, verify
the shift forks are square. If shift fork does not rest directly
on the square, then it is bent and must be replaced.
8.
Inspect shift drum and bearing. Replace shift drum
assembly if drum or bearing are damaged.
9.
Clean shift cam lock plate mounting holes in transmission
bearing housing.
10. Inspect side door bearings. Bearings must rotate freely
without drag. Replace the bearings if pitted, grooved or if
the shafts were removed.
sm03006
Figure 6-24. Checking Fork
ASSEMBLY
TOOL NAME
PART NUMBER
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586A
Installing Side Door Bearings
NOTES
•
Always replace side door bearing if the shaft was pressed
out.
•
To perform the next step, you must use a plate for support
or the bearing door will be damaged.
•
When pressing new bearings into side door, press on the
outside diameter of the bearing side with the numbers
stamped on it.
1.
Support the door from the opposite side at the bearing
bores with a flat plate.
2.
Position
new
bearing over bore with number side UP.
3.
Using a press, apply pressure to the outer diameter of the
bearing until the bearing is seated in the bore.
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)
4.
See
. Install beveled retaining ring (1) with the
flat side next to the bearing.
Countershaft
NOTES
•
Replace retaining ring and all gear roller bearings with
new parts during assembly. Lubricate needle bearings
and races with Screamin' Eagle Assembly Lube (Part No.
94971-090 before installation.
•
Install securing segments so the side with the rounded
edge is facing up and the side with the straight edge is
down. Be sure segments fully engage grooves in counter-
shaft.
•
One side of the 2nd, 3rd, and 4th gear lock rings have a
waved, stepped face. The waved, stepped face always
faces the securing segments.
1.
See
. Install
new
needle bearing, countershaft
4th gear (4), guiding hub (2), dog ring (3) securing seg-
ments and internal splined washer (1) on countershaft.
2.
See
. Install
new
needle bearing, countershaft
3rd gear (3), internal spline washer (2) and securing seg-
ments (1).
3.
See
. Place countershaft 3rd gear lock ring
over securing segments.
2011 Touring Service: Transmission 6-15
NOTES
•
In next step, the side of the guiding hub with the deeper
counterbore faces countershaft 2nd gear.
•
Countershaft 2nd gear bearing is wider than other bearings
on the countershaft.
4.
See
. Install
new
needle bearing, countershaft
2nd gear (4), guiding hub (2), dog ring (3) and securing
segments (1) on countershaft.
5.
See
. Place lock ring over securing segments
with the stepped face of the lock ring against the securing
segments.
6.
See
. Install
new
needle bearing, countershaft
1st gear (2) and washer (1).
NOTES
•
If installing countershaft only, hold countershaft 3rd and
4th gear shift dog up while pressing side door bearing on
to countershaft.
•
Failure to press on inner bearing races while pressing
bearings on the shafts will damage the bearings.
7.
See
. Place countershaft in an arbor press
supporting countershaft 6th gear. Using a suitable socket,
press on inner bearing race until side door bearing con-
tacts countershaft 1st gear washer.
sm03027a
Figure 6-25. Installing Countershaft
Mainshaft
NOTES
•
Failure to press on inner bearing race while pressing
bearing on the shaft will damage the bearing.
•
See
. Hold dog ring so that it is engaged with
countershaft 3rd gear during the press procedure. If press
is performed with dog ring engaged with countershaft 4th
gear, contact with mainshaft 4th gear will push shafts out
of alignment and result in possible bearing and gear
damage.
1.
Place mainshaft in an arbor press, supporting mainshaft
4th gear.
2.
Place rear side door bearing over mainshaft. Using a
suitable socket, press on inner bearing race until side door
bearing contacts mainshaft 1st gear.
3.
See
. With side door on end (shafts pointing
upward), install
new
bearing and mainshaft 5th gear (4).
4.
Be sure guiding hub counterbore is facing mainshaft 5th
gear and install guiding hub (2) and dog ring (3).
5.
Install
new
retaining ring using TRANSMISSION SHAFT
RETAINING RING PLIERS (Part No. J-5586A) (1).
sm02860a
Figure 6-26. Raise and Hold Dog Ring
Shifter Cam/Shifter Forks
1.
Using dog rings, lock two gears in place. Temporarily place
transmission assembly into transmission case.
2.
Install
new
nuts on mainshaft and countershaft. Tighten
nuts to 85-95 ft-lbs (115.3-128.8 Nm).
3.
Remove transmission assembly from case.
4.
Place side door on bench with shafts pointing upward.
5.
If removed, install detent arm assembly:
a.
See
. Clean detent screw mounting hole
in transmission side door.
b.
Assemble
new
detent screw, detent arm, sleeve and
detent spring. Mount detent assembly in bearing
housing as shown. Make certain to orient spring and
detent arm as shown in the figure. Tighten screw to
120-150
in-lbs
(13.6-17.0 Nm).
6.
See
. Using screwdriver (1), pull detent arm
back to allow installation of shift cam assembly.
7.
Install shift cam assembly (5).
8.
See
. Install lock plate (2) and
new
lock plate
fasteners (3). Tighten fasteners to 57-63
in-lbs
(6.4-7.1
Nm).
6-16 2011 Touring Service: Transmission
9.
See
. The forks are different from each other
and are identified as shown.
10. See
. Insert shifter fork (2) into the slot of the
dog ring in between mainshaft 5th and 6th gear. Slide long
shift shaft through 5th and 6th gear shifter fork and install
shaft in hole in side door.
11. Insert shifter fork (6) into the slot of the dog ring in between
countershaft 3rd and 4th gear. Insert shifter fork (9) into
the slot of the dog ring in between countershaft 1st and
2nd gear. Slide short shift shaft through countershaft shifter
forks and install shaft in hole in side door.
NOTE
If main drive gear was removed, install it now. See
.
1
2
4
3
sm03018
1. Detent screw
2. Detent arm
3. Sleeve
4. Detent spring
Figure 6-27. Detent Assembly
2
1
5
4
3
sm03601a
1. Screwdriver
2. Detent fastener
3. Detent spring
4. Detent arm
5. Shift cam
Figure 6-28. Detent Assembly
2011 Touring Service: Transmission 6-17
1
3
3
2
4
sm03600a
1. Side door
2. Lock plate
3. Lock plate fastener (2)
4. Shift cam
Figure 6-29. Shift Drum
1
3
4
5
2
sm03028
1. Long shift shaft
2. 5th and 6th gear shifter fork
3. Short shift shaft
4. 3rd and 4th gear shifter fork
5. 1st and 2nd gear shifter fork
Figure 6-30. Shifter Forks and Shafts
6-18 2011 Touring Service: Transmission
2
10
5
4
1
7
6
3
8
9
sm03029a
1. Long shift shaft
2. 5th and 6th gear shifter fork
3. 5th gear
4. Short shift shaft
5. 5th gear
6. 3rd and 4th gear shifter fork
7. 3rd gear
8. 2nd gear
9. 1st and 2nd gear shifter fork
10. 1st gear
Figure 6-31. Transmission Gears and Shifter Forks
INSTALLATION
1.
Cover mainshaft clutch hub splines with tape to prevent
the splines damaging the main drive gear oil seal.
2.
Verify that two ring dowels are in place on side door flange.
Place a
new
gasket on the ring dowels.
3.
Apply clean transmission lubricant to the main drive gear
bearings.
NOTE
Be sure the transmission filler plug/dipstick is removed before
installing transmission assembly. Contact with the filler
plug/dipstick will prevent installation of transmission assembly.
4.
Install the transmission assembly in the transmission case
with a
new
gasket.
5.
See
. Install exhaust bracket using long screws
(1). Install remaining side door screws (2).
6.
See
. Tighten all side door hardware in the
sequence shown to 13-18 ft-lbs (17.6-24.4 Nm).
2
2
2
1
sm03669
1. Long screw (2)
2. Short screw (6)
Figure 6-32. Side Door hardware
5
7
2
4
6
8
1
3
sm05044
Figure 6-33. Side Door Torque Sequence
7.
Install mainshaft bearing inner race. See
8.
See
. Install push rod assembly (items 2-5) in
mainshaft hole. Secure with
new
retaining ring (1) if
removed.
9.
Install the clutch release cover, using a
new
gasket. See
10. Rotate shifter cam pawl forward and lower into place on
shift cam. Install
new
transmission top cover gasket. Install
transmission top cover. Tighten fasteners to 90-120
in-lbs
(10.2-13.6 Nm).
11. Install vent hose to top cover fitting, if removed.
12. Install transmission sprocket nut. See
2011 Touring Service: Transmission 6-19
13. Install primary chaincase, clutch assembly and primary
cover. See
5.3 PRIMARY CHAINCASE COVER, Installa-
.
14. Replace O-ring on plug. Clean and install transmission
drain plug. Tighten to 14-21 ft-lbs (19.0-28.5 Nm).
15. Fill transmission to proper level with fresh transmission
fluid. See
.
16. Adjust drive belt tension. See
17. Install exhaust system. See
.
4
1
3
5
6
2
sm03013
1. Retaining ring
2. Thrust washer (2)
3. Throw out bearing
4. Oil slinger
5. Push rod
6. Push rod end, left side
Figure 6-34. Push Rod Assembly
6-20 2011 Touring Service: Transmission
6.7
MAIN DRIVE GEAR AND BEARING
REMOVAL
TOOL NAME
PART NUMBER
PILOT
HD-35316-10
RECEIVER CUP
HD-35316-11
CROSS PLATE
HD-35316-3A
8 IN. BOLT
HD-35316-4A
12 IN. BOLT
HD-35316-5
WASHER
HD-35316-7
BEARING DRIVER
HD-35316-9
MAIN DRIVE GEAR/BEARING
REMOVER AND INSTALLER
HD-35316-C
LONG BOLTS
HD-95637-10
WEDGE ATTACHMENT
HD-95637-46B
BEARING
RS-25100-200
NOTE
Leave the transmission case in the frame unless the case itself
must be replaced. For illustration purposes, some photographs
may show the case removed.
1.
Remove the exhaust system. See
2.
Remove the primary chaincase cover, clutch assembly,
primary chain, compensating sprocket, and primary
chaincase. See
.
3.
Remove the bearing inner race from the transmission
mainshaft. See
5.5 PRIMARY CHAINCASE HOUSING,
4.
Remove the transmission side door. See
Failure to use Main Drive Gear Remover and Installer can
cause premature failure of bearing and related parts.
(00540b)
NOTE
Main drive gear and bearing can be removed with the transmis-
sion case in the frame after removing door assembly. Use
MAIN
DRIVE
GEAR/BEARING
REMOVER
AND
INSTALLER (Part No. HD-35316-C).
5.
Remove retaining ring.
NOTES
•
The main drive gear bearing and retaining ring must be
replaced if the main drive gear is removed. The bearing
will be damaged during the removal procedure.
•
The CROSS PLATE (Part No. HD-35316-3A) is stamped,
"UP 6 SPEED". Mount cross plate with this end pointing
up.
6.
See
. Place CROSS PLATE (Part No. HD-
35316-3A) (1) on right side of transmission case as shown,
and secure with two screws (2). Position cross plate so
that large bolt hole in cross plate is lined up with center of
main drive gear (4).
7.
Apply a light coat of graphite lubricant to the threads of
the 12 IN. BOLT (Part No. HD-35316-5) (3) and insert
through cross plate and main drive gear.
8.
At left side of transmission case, place WASHER (Part
No. HD-35316-7), BEARING (Part No. RS-25100-200)
(6), flat washer (7) and nut (8) over end of bolt. Tighten
nut until main drive gear is free.
NOTES
•
When removing the main drive gear, the gear is pressed
out against the resistance of the bearing inner race.
Without any support at the inner race, the bearing is des-
troyed. Whenever the main drive gear is removed the main
drive gear bearing must also be replaced.
•
See
. When the main drive gear is removed,
a portion of the bearing inner race remains attached to
the main drive gear. If the main drive gear is to be re-used,
this inner race must be removed first.
9.
Remove tool and remove gear from gearcase.
10. See
. Use WEDGE ATTACHMENT (Part
No. HD-95637-46B) and LONG BOLTS (Part No. HD-
95637-10) to remove inner race from main drive gear.
11. Remove large main drive gear oil seal.
12. Remove retaining ring from bearing bore.
13. See
. Slide PILOT (Part No. HD-35316-10) (3)
over small end of BEARING DRIVER (Part No. HD-35316-
9) (2).
14. Apply a light coat of graphite lubricant to the threads of
the 8 IN. BOLT (Part No. HD-35316-4A) (1) and insert
through bearing driver and pilot.
15. Insert bolt with bearing driver and pilot into right side of
transmission case, through main drive gear bearing (4).
Make sure bearing driver fits up against main drive gear
bearing and pilot is centered in bearing bore.
16. At left side of case, slide RECEIVER CUP (Part No. HD-
35316-11) (5) onto bolt and over main drive gear bearing.
Install BEARING (Part No. RS-25100-200) (6), flat washer
(7) and nut (8) over end of bolt.
NOTE
Support bearing remover assembly as you remove bearing in
the following step. Entire assembly will fall out of transmission
case when bearing comes free.
17. Tighten nut until main drive gear bearing is free.
18. Discard main drive gear bearing.
2011 Touring Service: Transmission 6-21
8
1
6
5
7
3
2
4
4
sm03033
1. Cross plate
2. Screw (2)
3. 12 in. bolt
4. Main drive gear
5. Washer
6. Bearing
7. Flat washer
8. Nut
Figure 6-35. Removing Main Drive Gear
2
1
3
4
sm03034
1. Main drive gear
2. Long bolt (2)
3. Wedge attachment
4. Press ram
Figure 6-36. Removing Inner Bearing Race From Main Drive
Gear
8
5
4
2
3
1
6
7
sm03035
1. 8 in. Bolt
2. Bearing driver
3. Pilot
4. Main drive gear bearing
5. Receiver cup
6. Bearing
7. Flat washer
8. Nut
Figure 6-37. Removing Main Drive Gear Bearing
CLEANING AND INSPECTION
TOOL NAME
PART NUMBER
MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL
HD-47932
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 solvent except the transmission case
and needle bearings. Blow dry with compressed air.
NOTE
Never wash the transmission case and needle bearings with
solvent unless the needle bearings are to be replaced. Normal
cleaning methods will wash dirt or other contaminants into the
bearing case (behind the needles) and leads to bearing failure.
2.
Inspect the main drive gear for pitting and wear. Replace
if necessary.
3.
Inspect the needle bearings inside the main drive gear.
Replace the needle bearings if the mainshaft race is pitted
or grooved.
6-22 2011 Touring Service: Transmission
4.
Replace the sprocket if teeth are cracked or worn. See
5.7 TRANSMISSION SPROCKET, Cleaning and Inspec-
tion
for more information.
5.
Inspect the needle bearings on the inside of the main drive
gear. If mainshaft race surface appears pitted or grooved,
replace these bearings.
NOTE
If the main drive gear needle bearings and/or seal need to be
replaced, continue as follows. Otherwise, proceed to
6.8 TRANSMISSION CASE, Assembly
.
Needle Bearing Replacement
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
•
See
. When replacing needle bearings, discard
original retaining rings (1) and install replacement retaining
rings (2).
•
To install the inner main drive gear needle bearings and
mainshaft seal, use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (Part No. HD-47932).
1.
See
. Remove mainshaft seal (6). Remove
retaining rings (1), needle bearings (2) and spacer (5) from
main drive gear (3). Discard retaining rings.
2.
Remove and discard O-ring (4).
1
2
3
4
2
1
6
5
sm03036
1. Retaining ring (2)
2. Needle bearing (2)
3. Main drive gear
4. O-ring
5. Spacer
6. Mainshaft seal
Figure 6-38. Main Drive Gear Assembly
1
2
sm03038
1. Original retaining ring
2. Replacement retaining ring
Figure 6-39. Main Drive Gear Retaining Rings
3.
See
. Install clutch side needle bearing using
an arbor press and the 0.400 in. step end of tool as shown.
Press until tool contacts gear.
sm03040
Figure 6-40. Installing Clutch Side Needle Bearing in Main
Drive Gear
NOTE
An alternative method is provided which allows the mainshaft
seal to be pressed into place after installation of the main drive
gear. See
6.7 MAIN DRIVE GEAR AND BEARING, Mainshaft
.
4.
See
. Turn over tool and press in mainshaft
seal using the 0.090 in. step with garter spring side down.
5.
Install spacer.
6.
See
. Turn over the main drive gear in the arbor
press. With the tool at the 0.188 in. step, press inner
bearing until tool contacts gear.
2011 Touring Service: Transmission 6-23
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