Harley Davidson Sportster Models 2009. Service Repair Manual — page 66
5.9
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) and the appropriate engine stand.
3.
Disassemble top end. See
4.
Remove primary cover, clutch assembly, primary chain
and engine sprocket. See
5.
Disassemble gearcase. See
.
6.
Remove transmission sprocket.
7.
. 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.
. 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 5-49. Countershaft Retaining Screw
1
2
sm03355
1.
Neutral indicator switch
2.
Neutral switch connector
Figure 5-50. Neutral Switch and Connector
sm03356
Figure 5-51. Shifter Drum Neutral Detent
10. See
and
. Depress ratchet arms
(item 2,
) in order to clear the shifter drum, and
remove shifter shaft assembly from left crankcase 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.
2009 Sportster Service: Drive/Transmission 5-37
3
1
2
sm03357
1.
Shifter shaft
2.
Ratchet arms
3.
Return spring
Figure 5-52. Shifter Shaft Assembly
sm01323
Figure 5-53. Removing Shifter Shaft Assembly
sm03359
Figure 5-54. Scribed Line on Shifter Drum at 12 o'clock
5-38 2009 Sportster Service: Drive/Transmission
1
2
4
3
5
sm03405
4.
1.
Short fastener
Left side
2.
5.
Right side
XR Models: double-headed bolt
3.
Indicates crankcase fastener locations
Figure 5-55. 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.
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.
sm01506
Figure 5-56. Separating Crankcase Halves
2009 Sportster Service: Drive/Transmission 5-39
sm01505
Figure 5-57. Removing Flywheel Assembly From Right
Crankcase Half (typical, XL model shown)
16. See
. Remove screw (1), gear detent assembly
(2) and detent spring (3) from inside transmission cavity
of right crankcase (4).
4
2
1
3
sm03671
1.
Screw
2.
Gear detent assembly
3.
Detent spring
4.
Right crankcase
Figure 5-58. Gear Detent Assembly
5-40 2009 Sportster Service: Drive/Transmission
5.10
TRANSMISSION REMOVAL AND DISASSEMBLY
TRANSMISSION REMOVAL FROM LEFT
CRANKCASE
TOOL NAME
PART NUMBER
TRANSMISSION REMOVER
B-43895-1
NOTE
. Shifter design allows for one common part
number for both countershaft shifter forks. As the transmission
runs, each shifter fork develops a certain wear pattern with its
mating parts. For this reason, it is important that each shifter
fork be reinstalled in its original location.
2
1
3
4
6
7
5
sm03368
1.
Mainshaft
2.
Mainshaft shifter fork (4/5)
3.
Drum (left side)
4.
Drum (right side)
5.
Countershaft
6.
Countershaft shifter fork (2/3)
7.
Countershaft shifter fork (1)
Figure 5-59. Shifter Forks, Drum and Shafts
1.
. 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.
sm03369
Figure 5-60. Slots For Removing Shifter Fork Shafts
2
2
1
3
4
5
sm03370
1.
Shifter drum
2.
Shifter fork (3)
3.
Mainshaft
4.
Mainshaft 2nd gear
5.
Countershaft
Figure 5-61. Transmission Assembly
2009 Sportster Service: Drive/Transmission 5-41
4
8
9
6
4
10
5
12
13
14
15
16
22
17
18
19
20
21
11
7
3
2
1
sm03371
12.
1.
Bushing
Detent spring
2.
13.
Detent spring sleeve assembly
Shifter stop pin
14.
3.
Shifter return spring
Screw
4.
15.
Shifter fork shaft (2)
Extension spring
16.
5.
Shifter lever assembly
Shifter fork (4th/5th)
6.
17.
Right hand crankcase bushing
Rubber washer
18.
7.
Screw
Shifter cam assembly
8.
19.
Shifter fork (1st)
Washer
20.
9.
Foot shift lever
Shifter fork (2nd/3rd)
10.
21.
Retaining ring
Shifter peg
22.
11.
Oil seal
Bearing
Figure 5-62. Shifter Mechanism
5-42 2009 Sportster Service: Drive/Transmission
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 5-63. 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)
3.
. 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 TRANSMISSION
REMOVER (Part No. B-43895-1) (2) to remove
transmission assembly from crankcase half.
c.
Remove crankcase from press.
2009 Sportster Service: Drive/Transmission 5-43
18
19
20
12
12
10
9
10
10
9
22
23
25
24
27
2
3
21
4
32
8
9
26
10
5
1
6
13
14
15
16
17
12
12
7
11
6
33
35
34
28
29
30
31
9
sm03374
25.
13.
1.
Dog ring
Mainshaft
Oil seal
2.
26.
14.
Retaining ring
Thrust washer
Mainshaft 3rd gear (integral to
shaft)
3.
27.
Ball bearing (XL models)
Countershaft 2nd gear
15.
28.
Mainshaft 2nd gear (integral to
shaft)
4.
Spacer
O-ring
5.
29.
Oil seal
Countershaft bearing
16.
30.
Mainshaft bearing
6.
Retaining ring
Needle bearing (2)
7.
31.
17.
Mainshaft 5th gear
Countershaft retaining screw
Retaining ring
18.
8.
32.
Closed end bearing
Mainshaft 1st gear
Retaining ring
33.
19.
9.
Spacer (XR models)
Countershaft 5th gear (integral
to shaft)
Retaining ring (4)
10.
34.
Thrust washer (4)
O-ring (XR models)
20.
35.
Countershaft
11.
Double roller bearing (XR
models)
Mainshaft 4th gear
12.
21.
Split bearing (4)
Countershaft 1st gear
22. Dog ring
23. Countershaft 4th gear
24. Countershaft 3rd gear
Figure 5-64. Transmission Assembly
MAINSHAFT/COUNTERSHAFT
NOTES
•
As the transmission runs, each part develops a certain
wear pattern and a kind of "set" with its mating parts. For
this reason, it is important that each component be rein-
stalled in its original location and facing its original direc-
tion.
•
. As each component is removed, place
it on a clean surface in the exact order of removal.
5-44 2009 Sportster Service: Drive/Transmission
1
2
sm03373
1.
Mainshaft
2.
Countershaft
Figure 5-65. 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.
•
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.
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 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.
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 5-66. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly
2009 Sportster Service: Drive/Transmission 5-45
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 and blow dry with
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 on the gears. Replace the gears
if dogs are rounded, cracked, battered, chipped or dimpled.
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.
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. If gears are pitted, scored,
rounded, cracked or chipped, they should be replaced.
3.
Inspect the engaging dogs on the gears. Replace the gears
if dogs are rounded, cracked, battered, chipped or dimpled.
5-46 2009 Sportster Service: Drive/Transmission
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 5-67. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
2009 Sportster Service: Drive/Transmission 5-47
5.11
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.
•
During assembly, the split bearings and the internal bores
of the gears must be lubricated with Harley-Davidson
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT prior to assembly. Leaving these parts
dry could accelerate wear at start-up.
1.
. 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 5-68. 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 Harley-Davidson
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT prior to assembly. Leaving these parts
dry could accelerate wear at start-up.
1.
. Install new split bearing (3) in 1st gear
position on mainshaft.
2.
Install 1st gear (4) and thrust washer (5).
5-48 2009 Sportster Service: Drive/Transmission
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).
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 5-69. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
2009 Sportster Service: Drive/Transmission 5-49
5.12
MAIN DRIVE GEAR AND BEARING
GENERAL
NOTE
. When removing the main drive gear (2), the
gear is pressed out against the resistance of the ball bearing
(7 or 14) inner race. Without any support at the inner race, the
bearing is destroyed. Whenever the main drive gear is removed
the main drive gear bearing must also be replaced.
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 models)
Shifter drum bushing
6.
13.
Right crankcase
O-ring (XR models)
14.
7.
Double roller bearing (XR models)
Ball bearing (XL models)
Figure 5-70. Main Drive Gear and Bearing Assembly
5-50 2009 Sportster Service: Drive/Transmission
REMOVAL
TOOL NAME
PART NUMBER
CROSS PLATE
B-45847
RECEIVER CUP
HD-35316-11
BEARING DRIVER
HD-35316-13
8 IN. 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.
. 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 cross plate so that roll pins (2) fit into
crankcase mating screw holes and bolt hole (3) in cross
plate 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 5-71. Main Drive Gear Assembly (typical)
4.
See
. Insert 8 IN. 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), NICE 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 5-72. Positioning Cross Plate (typical)
1
2
7
3
4
5
6
sm01304
1.
Cross plate
2.
8 in. bolt
3.
Main drive gear
4.
Washer
5.
Nice bearing
6.
Washer
7.
Nut
Figure 5-73. Removing Main Drive Gear (typical)
2009 Sportster Service: Drive/Transmission 5-51
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.
. Remove and discard oil seal (10).
Remove and discard main drive gear bearing retaining
ring (9).
2.
XR Models: remove spacer (12) and o-ring (13).
3.
. Install driver components: From inside
crankcase, position bearing driver (2) over main drive gear
bearing.
a.
XL Models:BEARING DRIVER (Part No. HD-35316-
9).
b.
XR Models:BEARING DRIVER (Part No. HD-35316-
13).
4.
Insert 8 IN. 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 NICE
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.
1
2
3
5
4
6
sm01305
1.
8 in. bolt
2.
Bearing driver
3.
Receiver cup
4.
Nice bearing
5.
Flat washer
6.
Nut
Figure 5-74. Removing Main Drive Gear Bearing (typical,
XL model shown)
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) using appropriate bearing and
bushing puller. 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. This inner
race must be removed before the main drive gear can be re-
installed.
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
3
1
sm01306
1.
Main drive gear
2.
Inner bearing race (not visible in this photo)
3.
Bearing race puller
4.
Press ram
Figure 5-75. Removing Inner Bearing Race From Main Drive
Gear (typical)
5-52 2009 Sportster Service: Drive/Transmission
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст