Harley Davidson 2006 Sportster XLH MODELS. Service Manual — page 23
HOME
MAIN DRIVE GEAR AND BEARING
6.11
GENERAL
NOTE
See Figure 6-46. When removing the main drive gear (2), the
gear is pressed out against the resistance of the ball bearing
(7) 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.
x0587b6x
11
1
3
6
4
1
7
2
9
10
5
8
1.
Needle bearing (2)
7.
Ball bearing
2.
Main drive gear
8.
Countershaft bearing (closed end)
3.
O-ring
9.
Retaining ring
4.
Oil seal
10. Oil seal
5.
Shifter drum bushing
11. Retaining ring
6.
Right crankcase
Figure 6-46. Main Drive Gear and Bearing Assembly
2006 Sportster: Drive/Transmission
6-33
HOME
REMOVAL
11505
Main Drive Gear
1
3
PART NO.
SPECIALTY TOOL
HD-35316-C
Main drive gear remover and installer
B-45847
Cross plate
HD-47855
Inner/outer main drive gear needle
4
bearing installation tool
1.
Split crankcases. See 6.8 CASE DISASSEMBLY FOR
TRANSMISSION REMOVAL.
2
2.
See Figure 6-47. 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. See Figure
6-48. Place CROSS
1.
Cross plate (Part No. B-45847)
PLATE (1) on right crankcase as shown. Position cross
2.
Roll pin (2)
plate so that roll pins (2) fit into crankcase mating screw
3.
Bolt hole
holes and bolt hole (3) in cross plate is centered over
4.
Main drive gear
main drive gear (4).
Figure 6-48. Positioning Cross Plate
x0669x6x
2
11506
1
6
7
3
5
4
1
2
1.
Main drive gear
2.
Needle bearing (2)
3.
Seal
3
5
4.
O-ring
4
5.
Retaining ring
Figure 6-47. Main Drive Gear Assembly
1. Cross plate (Part No. B-45847)
2.
8 in. bolt (Part No. HD-35316-4A)
4.
See Figure 6-49. Insert 8 IN. BOLT (Part No. HD-35316-
3.
Main drive gear
4A) (2) through cross plate (1) and main drive gear (3).
4.
Washer (Part No. HD-35316-7)
5.
At outside of case, place WASHER (Part No. HD-35316-
5.
Nice bearing
7) (4), NICE BEARING (5), FLAT WASHER (6) and NUT
6.
Washer
(7) over end of bolt. Tighten nut until main drive gear is
7.
Nut
free.
Figure 6-49. Removing Main Drive Gear Bearing
6-34
2006 Sportster: Drive/Transmission
HOME
Main Drive Gear Ball Bearing
DISASSEMBLY
1WARNING
Wear safety glasses or goggles when removing or install-
PART NO.
SPECIALTY TOOL
ing retaining rings. Retaining rings can slip from the pli-
HD-95637-46A
Bearing race puller
ers and could be propelled with enough force to cause
serious eye injury. (00312a)
1. See Figure
6-46. Remove retaining ring
(11) from
NOTE
inboard end of main drive gear (2). Discard retaining
Use correct retaining ring pliers and correct tips. Verify that
ring.
tips are not excessively worn or damaged.
2. See Figure 6-47. Drive out needle bearings (2) from
1.
See Figure 6-46. At outside of case remove and discard
inside bore of main drive gear (1) using appropriate bear-
oil seal (10). Remove and discard main drive gear bear-
ing and bushing puller. Discard needle bearings. Do not
ing retaining ring (9).
reuse bearings after removal from drive gear bore.
2.
See Figure 6-50. From inside crankcase, position BEAR-
3. Remove and discard O-ring (4).
ING DRIVER (Part No. HD-035316-9) (2) over main drive
NOTE
gear ball bearing.
When the main drive gear is removed, a portion of the bear-
3.
Insert 8 IN. BOLT (Part No. HD-35316-4A) (1) through
ing inner race remains attached to the main drive gear. This
bearing driver and bearing.
inner race must be removed before the main drive gear can
4.
At outside of case, slide RECEIVER CUP (Part No. HD-
be re-installed.
35316-11) (3) onto bolt and over bearing. Install NICE
4. See Figure 6-51. Attach BEARING RACE PULLER (3) to
BEARING (4), FLAT WASHER (5) and NUT (6) over end
inner race (2) on main drive gear (1).
of bolt.
5. Place main drive gear with bearing race puller assembly
NOTE
onto press bed as shown in the photo.
Support bearing remover assembly as you remove bearing in
the following step. Entire assembly will fall out of crankcase
NOTE
when bearing comes free.
Provide a soft surface to catch the main drive gear when it
falls free in the next step.
5.
Tighten nut until main drive gear ball bearing is free.
6.
Discard main drive gear ball bearing.
6. Press main drive gear out of inner bearing race. Discard
inner bearing race.
11507
3
5
11516
4
2
1
2
4
6
11508
1.
8 in. Bolt (Part No. HD-35316-4A)
2.
Bearing driver (Part No. HD-35316-9)
3.
Receiver cup (Part No. HD-35316-11)
4.
Nice bearing
5.
Flat washer
6.
Nut
3
Figure 6-50. Removing Main Drive Gear Bearing
1
1.
Main drive gear
2.
Inner bearing race (not visible in this photo)
3.
Bearing race puller (Part no. HD-95637-46A)
4.
Press ram
Figure 6-51. Removing Inner Bearing Race
From Main Drive Gear
2006 Sportster: Drive/Transmission
6-35
HOME
4. See Figure 6-53. Place main drive gear (4) on press bed
ASSEMBLY
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
PART NO.
SPECIALTY TOOL
lettered side of bearing to install. Insert installation tool
(2) with end stamped “OUTER” facing needle bearing.
HD-47855
Inner/outer main drive gear needle
6. Press in the outer needle bearing until the installation
bearing installation tool
tool bottoms on the main drive gear. The surface of the
needle bearing will be at a depth of 0.285 in. (7.239 mm)
Use INNER/OUTER MAIN DRIVE GEAR NEEDLE BEAR-
from the end of the main drive gear.
ING INSTALLATION TOOL as follows. The installation tool will
7. See Figure
6-46. Install new retaining ring
(11) in
automatically bottom on the gear when the correct depth is
inboard end of main drive gear (2).
reached.
1.
See Figure 6-52. Place main drive gear (4) on press bed
with gear end facing up.
11477
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 MAIN DRIVE
GEAR NEEDLE BEARING INSTALLER (2) with end
stamped “INNER” facing needle bearing.
1
2
3.
Press in the inner bearing until the installation tool bot-
toms on the main drive gear. The surface of the needle
bearing will be at a depth of 0.170 in. (4.318 mm) from
3
the face of the shifter dogs on the main drive gear.
4
11477
1
2
1. Press ram
2. Needle bearing installation tool
3
(Part No. HD-47855)
3. Needle bearing
4. Main drive gear
Figure 6-53. Pressing Outer Needle Bearing
4
Assembly into Main Drive Gear
1.
Press ram
2.
Needle bearing installation tool
(Part No. HD-47855)
3.
Needle bearing
4.
Main drive gear
Figure 6-52. Pressing Inner Needle Bearing
Assembly into Main Drive Gear
6-36
2006 Sportster: Drive/Transmission
HOME
INSTALLATION
11514
Main Drive Gear Ball Bearing
1
3
PART NO.
SPECIALTY TOOL
HD-35316-C
Main drive gear remover and installer
B-45847
Cross plate
4
HD-47856
Main drive gear seal installer
1.
See Figure 6-54. Place CROSS PLATE (1) on right
crankcase as shown. Position cross plate so that roll pins
2
(2) fit into crankcase mating screw holes and bolt hole (3)
in cross plate is centered over crankcase bearing bore
(4).
2.
See Figure 6-55. Insert 8 IN. BOLT (Part No. HD-35316-
4A) (2) through cross plate (1) and main drive gear bear-
1.
Cross plate (Part No. B-45847)
ing bore.
2.
Roll pin (2)
3.
At outside of case, place main drive gear ball bearing (3),
3.
Bolt hole
BEARING DRIVER (Part No. HD-35316-8) (4), NICE
4.
Crankcase bearing bore
BEARING (5), FLAT WASHER (6) and NUT (7) over end
Figure 6-54. Positioning Cross Plate
of bolt.
CAUTION
11511
Do not continue to tighten nut after ball bearing bottoms
4
against lip in crankcase bearing bore. Tightening nut too
1
much can break lip in bearing bore casting.
3
4.
Tighten nut until main drive gear ball bearing bottoms
against lip cast into crankcase bearing bore.
5.
Remove main drive gear bearing installer tool.
1WARNING
Wear safety glasses or goggles when removing or install-
ing retaining rings. Retaining rings can slip from the pli-
ers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTE
2
5
6
7
Use correct retaining ring pliers and correct tips. Verify that
tips are not excessively worn or damaged.
1. Cross plate (Part No. B-45847)
6.
See Figure 6-46. At outside of case install new beveled
2.
8 in. bolt (Part No. HD-35316-4A)
retaining ring (9) in groove inside bearing bore with bev-
3.
Main drive gear bearing
eled side facing outside of case.
4.
Bearing driver (Part No. HD-35316-8)
7.
Lubricate main drive gear ball bearing with GENUINE
5.
Nice bearing
HARLEY-DAVIDSON FORMULA+ TRANSMISSION
6. Flat washer
AND PRIMARY CHAINCASE LUBRICANT.
7. Nut
Figure 6-55. Installing Main Drive Gear Bearing
2006 Sportster: Drive/Transmission
6-37
HOME
Main Drive Gear
12003
1.
See Figure 6-56. Lubricate both main drive gear needle
bearing assemblies with HARLEY-DAVIDSON SPECIAL
PURPOSE GREASE.
2.
See Figure 6-57. Install new O-ring (3) into groove in
main drive gear (2). Lubricate O-ring with GENUINE
HARLEY-DAVIDSON FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT.
NOTE
See Figure 6-57. Make sure to install new O-ring (3) onto
main drive gear (2) and lubricate O-ring with GENUINE HAR-
LEY-DAVIDSON FORMULA+ TRANSMISSION AND PRI-
MARY CHAINCASE LUBRICANT before installing main drive
gear into crankcase.
Figure 6-56. Lubricating Main Drive Gear Needle Bearings
x0587b6x
11
1
3
6
4
1
7
2
9
10
5
8
1.
Needle bearing (2)
7. Ball bearing
2.
Main drive gear
8. Countershaft bearing (closed end)
3.
O-ring
9. Retaining ring
4.
Oil seal
10. Oil seal
5.
Shifter drum bushing
11. Retaining ring
6.
Right crankcase
Figure 6-57. Main Drive Gear and Bearing Assembly
6-38
2006 Sportster: Drive/Transmission
HOME
3.
See Figure 6-58. Insert 8 IN. BOLT (Part No. HD-35316-
12040
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), NICE BEARING (5), FLAT WASHER (6)
and NUT (7) over end of bolt. Tighten nut until main drive
gear bottoms against main drive gear bearing.
5.
Remove MAIN DRIVE GEAR REMOVER AND
INSTALLER set.
6.
See Figure 6-57. 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).
Figure 6-59. Install Pilot (Part No. HD-47856-2)
11509
6
4
12041
1
3
2
5
7
11510
1.
8 in. bolt (Part No. HD-35316-4A)
2.
Washer (Part No. HD-35316-7)
3.
Main drive gear
4.
Installer cup (Part No. HD-35316-12)
5.
Nice bearing
6.
Flat washer
7.
Nut
Figure 6-58. Installing Main Drive Gear
Figure 6-60. Install Main Drive Gear Seal
Main Drive Gear Seal
1.
See Figure 6-59. From outside of crankcase, install
12042
PILOT (Part No. HD-47856-2) over end of main drive
gear bearing inner race.
2.
Coat lips of new main drive gear seal with GENUINE
HARLEY-DAVIDSON FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT.
3.
See Figure 6-60. 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.
4.
See Figure 6-61. 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.
Figure 6-61. Install Adapter (Part No. HD-47856-4)
2006 Sportster: Drive/Transmission
6-39
HOME
5.
See Figure 6-62. Slide INSTALLER (Part No. HD-47856-
12044
1) over adapter until cupped end of installer is flat against
seal.
6.
See Figure 6-63. Thread large nut (Part No. HD-47856-
5) onto end of adapter, until it tightens against installer.
7.
See Figure 6-64. Place crow’s foot wrench (1) with 1/2
inch drive breaker bar (2) on large nut. Place an adjust-
able wrench (3) on flats of hex head cast into end of
adapter.
8.
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.
Figure 6-63. Install Nut (Part No. HD-47856-5)
9.
Remove nut, installer, adapter and pilot.
12043
12089
1
2
3
Figure 6-62. Place Installer (Part No. HD-47856-1)
over Adapter
1.
Crowfoot wrench
2.
1/2 inch breaker bar
3.
Adjustable wrench
Figure 6-64. Press Seal Into Crankcase
6-40
2006 Sportster: Drive/Transmission
HOME
TRANSMISSION RIGHT CASE BEARINGS
6.12
REMOVAL
INSTALLATION
Countershaft Needle Bearing
PART NO.
SPECIALTY TOOL
1. Find a suitable bearing driver 1-1/4 in. (31.75 mm) in
HD-95760-69A
Bushing and bearing puller
diameter.
2. See Figure 6-57. From the outside of the case place the
HD-95765-69A
1/2 in. collet
needle bearing (8) open end first next to the bearing
bore. Hold the driver squarely against the closed end of
Split crankcases. See
6.8 CASE DISASSEMBLY FOR
the bearing and tap the bearing into place. The bearing is
TRANSMISSION REMOVAL.
properly positioned when it is driven flush or 0.030 in.
Countershaft Needle Bearing
(0.762 mm) below the outside surface of the case.
3. Lubricate bearing with GENUINE HARLEY-DAVIDSON
See Figure 6-57. From inside transmission case use appro-
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
priate bearing driver/puller to remove countershaft bearing (8)
CASE LUBRICANT.
from crankcase bore.
Shifter Drum Bushing
Shifter Drum Bushing
1. See Figure 6-57. Using SNAP-ON BUSHING DRIVER
1.
The shifter drum bushing (5) is a press fit in the right
SET (Part No. A-157C) with a 1/2 inch adapter (Part No.
crankcase half. Inspect the bushing against the corre-
A157-8), install new bushing (5).
sponding end of the shifter drum for proper fit and wear.
2. Lubricate bushing with GENUINE HARLEY-DAVIDSON
2.
If bushing is to be replaced, use BUSHING AND BEAR-
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
ING PULLER with 1/2 IN. COLLET to remove bushing
CASE LUBRICANT.
from crankcase bore.
2006 Sportster: Drive/Transmission
6-41
HOME
TRANSMISSION LEFT CASE BEARINGS
6.13
REMOVAL
a0123x6x
Mainshaft and Countershaft Bearings
1
1.
Split crankcases. See 6.8 CASE DISASSEMBLY FOR
3
TRANSMISSION REMOVAL.
2.
Remove shifter forks and drum. See 6.9 TRANSMIS-
SION REMOVAL AND DISASSEMBLY.
3.
Remove countershaft and mainshaft. See 6.9 TRANS-
2
4
MISSION REMOVAL AND DISASSEMBLY.
4.
Inspect the mainshaft and countershaft ball bearings for
pitting, scoring, discoloration or other damage.
5.
See Figure 6-65. If bearing replacement is required,
remove retaining rings (1, 2) using snap ring pliers (Snap
-On Part No. PR-36). Press out bearings (3, 4) from the
inside of the crankcase.
Shifter Drum Bushing
1.
Retaining ring
Inspect the shifter drum bushing for pitting, scoring, discolora-
2.
Retaining ring
tion or excessive wear. If bushing requires replacement press
3.
Mainshaft bearing
bushing out of crankcase from primary side toward inside of
4.
Countershaft bearing
case.
Figure 6-65. Ball Bearing Assembly
INSTALLATION
b1035x6x
Mainshaft and Countershaft Bearings
Press bushing to
1.
Place crankcase on press with inside surface of crank-
contact shoulder in
case downward.
crankcase half.
2.
Lay bearing squarely over bore with printed side of bear-
ing upward. Place a pressing tool (slightly smaller than
outside diameter of bearing) against outer race. Press
bearing into bore until bearing bottoms against shoulder.
3.
Install new retaining ring with beveled side facing away
from bearing.
Shifter drum
Shifter Drum Bushing
bushing
1.
Place crankcase on press with outside surface of crank-
Outside
case downward.
crankcase
2.
See Figure 6-66. Lay bushing squarely over bore. Using
a pressing tool larger than diameter of bushing, press
bushing into bore until bushing contacts shoulder in left
crankcase half. If using a pressing tool larger than diam-
eter of bushing, the pressing tool will bottom against
crankcase when bushing is flush with top surface.
Figure 6-66. Shifter Drum Bushing Assembly
6-42
2006 Sportster: Drive/Transmission
HOME
TRANSMISSION INSTALLATION
6.14
GENERAL
11534
NOTE
Before reinstalling transmission and reassembling crankcase
halves, perform any necessary engine overhaul procedures.
1
See 3.11 BOTTOM END SERVICE and 3.10 TOP END SER-
VICE.
After reassembling transmission, verify that all parts have
2
been properly installed. See Figure 6-41.
●
6.11 MAIN DRIVE GEAR AND BEARING
●
6.10 TRANSMISSION ASSEMBLY
●
6.12 TRANSMISSION RIGHT CASE BEARINGS
●
6.13 TRANSMISSION LEFT CASE BEARINGS
INSTALLATION
4
3
PART NO.
SPECIALTY TOOL
HD-46285
Transmission assembly fixture
B-43985
Transmission removal and installation tool
1.
See Figure 6-67. Place transmission assembly (2) onto
TRANSMISSION ASSEMBLY FIXTURE (3) on press
bed. Use support block(s) (4) if necessary.
1.
Countershaft guide (Part No. B-43985-4)
2.
Screw COUNTERSHAFT GUIDE (Part No. B-43985-4)
2.
Transmission assembly
(1) into end of countershaft.
3.
Transmission assembly fixture
(Part No. HD-46285)
4.
Support block(s)
Figure 6-67. Transmission Assembly on Fixture
2006 Sportster: Drive/Transmission
6-43
HOME
3.
See Figure 6-68. Install left crankcase (3) over transmis-
SHIFTER FORKS AND DRUM
sion assembly (4).
ASSEMBLY
4.
Place TRANSMISSION INSTALLER (2) over mainshaft
and countershaft bearings in crankcase.
5.
Position crankcase and transmission assemblies on
NOTES
press so that transmission installer is under press ram
● See Figure 6-69. Shifter design allows for one common
(1).
part number for both countershaft shifter forks. But as
the transmission runs, each shifter fork develops a cer-
tain wear pattern with its mating parts. For this reason, it
11535
is important that each shifter fork be reinstalled in its
original location.
2
● Always lubricate the shaft bore in each shifter fork with
1
GENUINE HARLEY-DAVIDSON FORMULA+ TRANS-
MISSION AND PRIMARY CHAINCASE
LUBRICANT
before assembly.
8616
4/5
5
3
4
Mainshaft
1.
Press ram
2.
Transmission installer (Part No. B-43985-3)
3.
Crankcase
4.
Transmission assembly
Left
Right
5.
Transmission assembly fixture
(Part No. HD-46285)
Figure 6-68. Pressing Transmission Into Left Crankcase
NOTE
Make sure crankcase does not begin to tilt when pressed
onto transmission assembly. It may be necessary to place
2-3
1
press ram on transmission installer closer to mainshaft to
keep the crankcase level.
6.
Press crankcase onto transmission assembly until shafts
bottom out on bearings.
7.
Remove left crankcase with transmission assembly from
press.
Countershaft
NOTE
When removing crankcase and transmission assembly from
fixture, make sure mainshaft 1st gear does not fall off shaft.
Gear could be damaged if it strikes a hard surface.
Figure 6-69. Shifter Forks, Drum and Shafts
6-44
2006 Sportster: Drive/Transmission
HOME
1.
Place 2nd/3rd gear shifter fork onto dog ring between
x0624a3x
countershaft 2nd and 3rd gears.
2.
Install shifter drum into left case half with previously
1
scribed line at 12o’clock position. This will place shifter
drum in neutral position.
NOTE
See Figure 6-70. 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 coun-
tershaft 1st and 4th gear gears. Install shifter fork shaft
2
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.
1. Detent assembly
11536
2. Detent assembly aid
Figure 6-71. Using Gear Detent Assembly Aid
(Part No. B-45520)
11522
Figure 6-70. Installing Shifter Fork Shafts
ASSEMBLING CRANKCASES
PART NO.
SPECIALTY TOOL
B-45520
Gear detent assembly aid
Figure 6-72. Installing Flywheel Assembly
HD-42326A
Crankshaft guide tool
In Right Crankcase
NOTE
See Figure 6-71. The GEAR DETENT ASSEMBLY AID is
used to move the gear detent lever clear of the shifter drum
for assembly purposes.
1.
See Figure 6-71. Retract detent assembly in right case
half and thread GEAR DETENT ASSEMBLY AID into
neutral switch hole until it has bottomed in right case half.
2.
See Figure 6-72. Install flywheel assembly into right
crankcase half.
2006 Sportster: Drive/Transmission
6-45
HOME
e. See Figure 6-74. Apply several drops of LOCTITE
1WARNING
262 (red) to last few threads of each crankcase fas-
tener and install fasteners in crankcase
(insert
Once the flywheel has been installed in the right crank-
eleven long and four short from left side, two long
case, do NOT rotate crankcase in stand so that flywheel
sprocket shaft is pointing down. Doing so can cause fly-
from right side), in locations shown.
wheel to fall out of crankcase which may result in death
f.
Tighten fasteners to 15-19 ft-lbs (20.3-25.8 Nm) in
or serious injury.
the sequence shown in Figure 6-74.
5. Remove GEAR DETENT ASSEMBLY AID and install
CAUTION
neutral indicator switch and flat washer. Tighten to 36-60
Transmission must be in first gear when assembling
in-lbs (4.0-6.8 Nm).
crankcases. If transmission is in neutral, shifter drum
detent will contact gear detent assembly aid when crank-
cases are assembled, possibly resulting in damage to
shifter drum assembly and/or crankcase.
11537
3.
Place Transmission in 1st gear.
4.
See Figure 6-73. Assemble crankcase halves together.
a. Slide CRANKSHAFT GUIDE TOOL (Part No. HD-
42326-A) onto flywheel sprocket shaft.
b. Apply a thin coat of GRAY HIGH-PERFORMANCE
SEALANT (Part No. 99650-02) to crankcase joint
faces.
c. Lubricate main drive gear inner bearings with GEN-
UINE HARLEY-DAVIDSON FORMULA+ TRANS-
MISSION
AND PRIMARY CHAINCASE
LUBRICANT.
d. Carefully fit crankcases together.
Figure 6-73. Assembling Crankcases With
Crankshaft Guide Tool (Part No. HD-42326-A)
x0568a3x
x0659x3x
Left side
8
16
7
9
11
12
17
6
10
13
5
Right side
15
14
*
*
*
1
2
3
4
- Indicates crankcase fastener locations
- Short fastener
*
Figure 6-74. Crankcase Fasteners
6-46
2006 Sportster: Drive/Transmission
HOME
SHIFTER SHAFT INSTALLATION
11316
1.
See Figure 6-75. Correctly install shifter return spring
onto the reverse side of the shifter shaft assembly before
placing shaft in left crankcase half.
Figure 6-77. Installing Shifter Shaft Assembly
b0950x6x
11315
Figure 6-75. Shifter Shaft Return Spring
(Correctly Installed)
CAUTION
See Figure 6-76. The shifter shaft return spring can be
installed incorrectly and then assembled in the left
crankcase half. Failure to install the spring properly will
result in improper shifting.
Figure 6-78. Countershaft Retaining Screw
3. See Figure 6-78. Apply several drops of LOCTITE 262
(red) to last few threads of countershaft retaining screw.
Thread screw into end of shaft.
4. Place transmission in gear and tighten screw (1) to 33-39
ft-lbs (44.8-52.9 Nm).
5. Install transmission sprocket. See 6.15 TRANSMISSION
SPROCKET.
6. Continue assembling engine. See appropriate sections
of
3.24 BOTTOM END OVERHAUL: ASSEMBLY and
b0951x6x
3.17 TOP END OVERHAUL: ASSEMBLY.
7. Install primary chain and engine sprocket, clutch assem-
Figure 6-76. Shifter Shaft Return Spring
bly, and primary cover. See
6.5 PRIMARY DRIVE/
(Incorrectly Installed)
CLUTCH.
2.
See Figure 6-77. Depress ratchet arms and insert shaft
8. Install engine in chassis. See 3.13 INSTALLING ENGINE
assembly into the bushing in the left case half and
IN CHASSIS.
release. Ratchet arms should now be inside the end
plate of the shifter drum contacting the shifter drum pins.
2006 Sportster: Drive/Transmission
6-47
HOME
TRANSMISSION SPROCKET
6.15
REMOVAL
11489
2
3
1
PART NO.
SPECIALTY TOOL
6
HD-46282
Transmission sprocket holding tool set
HD-46288
Mainshaft locknut wrench
1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, remove maxi-fuse before
4
proceeding. (00251a)
5
1.
Open left side cover and remove Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
2.
Shift transmission into neutral.
3.
Remove rear muffler and rear exhaust pipe. See 2.27
EXHAUST SYSTEM.
1.
Main drive gear shaft
4.
See Figure 6-79. Remove screw (6), washer (5) and
2.
Transmission sprocket
exhaust pipe clamp bracket (4). Remove two screws (2,
3.
Transmission sprocket nut
3) and remove sprocket cover (1).
4.
Lockplate
5.
Remove belt guard. See
2.30 BELT GUARD AND
5.
Screw (2)
DEBRIS DEFLECTOR.
6.
Screw and washer
6.
Remove rear drive belt from transmission sprocket. Pull
Figure 6-80. Transmission Sprocket Assembly
belt back out of the way. Do not bend belt too tightly or
twist belt. See 6.6 SECONDARY DRIVE BELT.
7.
See Figure 6-80. Remove screw and washer (6) from
exhaust interconnect bracket.
8.
Remove two screws (5) and sprocket lockplate (4).
x0256b6x
1
4
5
6
3
2
1.
Sprocket cover
2.
Screw
3.
Screw
4.
Exhaust pipe clamp bracket
5.
Washer
6.
Screw
Figure 6-79. Sprocket Cover
6-48
2006 Sportster: Drive/Transmission
HOME
9.
See Figure
6-81. Use TRANSMISSION SPROCKET
INSTALLATION
HOLDING TOOL (1), MAINSHAFT LOCKNUT WRENCH
(2), and a breaker bar
(3) to remove transmission
sprocket nut. Place handle of sprocket holding tool under
bottom of footpeg bracket. Turn nut clockwise to loosen
PART NO.
SPECIALTY TOOL
and remove it.
HD-46282
Transmission sprocket holding tool set
NOTES
● On models without rear footpegs, screw sprocket holding
HD-46288
Mainshaft locknut wrench
tool adapter (Part No. HD-46282-1) into bottom footpeg
bracket hole in frame. Place handle of tool underneath
1. See Figure 6-80. Install transmission sprocket (2) onto
adapter.
main drive gear shaft (1).
2. Shift transmission into neutral. Apply a few drops of
● If the engine has been removed from the motorcycle and
is mounted in the engine cradle (Part No. HD-42310-45),
LOCTITE THREADLOCKER 262 (red) to the left-hand
the rear crankcase support also serves as a tool stop for
threads of transmission sprocket nut (3). Position nut
the sprocket holding tool.
with washer-faced side facing transmission sprocket.
Turn the nut counterclockwise to install it onto main
drive gear shaft.
a. See Figure 6-82. Use TRANSMISSION SPROCKET
11493
HOLDING TOOL
(1), MAINSHAFT LOCKNUT
WRENCH (2), and a torque wrench (3). Place han-
3
dle of sprocket holding tool on top of footpeg
bracket. Tighten nut to 50 ft-lbs (67.8 Nm) initial
torque, ONLY.
NOTE
On models without rear footpegs, screw sprocket holding tool
1
adapter (Part No. HD-46282-1) into top footpeg bracket hole
in frame. Place handle of tool on top of adapter.
11494
3
2
1.
Transmission sprocket holding tool (HD-46282)
2.
Mainshaft locknut wrench (HD-46288)
3.
Breaker bar
Figure 6-81. Removing Transmission Locknut
1
2
1.
Transmission sprocket holding tool (HD-46282)
2.
Mainshaft locknut wrench (HD-46288)
3.
Torque wrench
Figure 6-82. Tightening Transmission Locknut
2006 Sportster: Drive/Transmission
6-49
HOME
b. See Figure 6-83. Scribe a line on the transmission
sprocket nut and continue the line on the transmis-
CAUTION
sion sprocket as shown.
Maximum allowable tightening of sprocket nut is 45° of
c. Tighten the transmission sprocket nut an additional
counterclockwise rotation, after initially tightening to 50
30° - 40°.
ft-lbs. Do not loosen sprocket nut while attempting to
d. See Figure 6-80. Install lockplate (4) over nut (3) so
align the screw holes. If you cannot align lockplate and
that two of lockplate’s four drilled holes (diagonally
sprocket screw holes, nut may be additionally tightened
opposite) align with sprocket’s (2) two tapped holes.
until screw holes line up, but do not exceed 45° as speci-
fied above. Tightening too much or little may cause the
NOTE
nut to come loose during vehicle operation.
The lockplate has four screw holes and can be turned to
either side, so you should be able to find a position without
e. Install socket head screws through two of the four
having to additionally tighten the nut. If you cannot align the
holes in lockplate, then into two corresponding
screw holes properly, the nut may be additionally TIGHT-
tapped holes in sprocket.
ENED until he screw holes line up, but do not exceed 45° as
specified above. Never LOOSEN nut to align the screw holes.
CAUTION
To ensure the lockplate’s security, you must use BOTH
screws when you install the lockplate.
x0285a6x
3. Tighten socket head screws
(5) to
90-110 in-lbs
2
(10.2-12.4 Nm).
4. Install screw and washer (6) to secure exhaust intercon-
nect bracket to engine crankcase. Tighten to 30-33 ft-lbs
(40.7-44.8 Nm).
5. Install rear drive belt onto transmission sprocket. See 6.6
SECONDARY DRIVE BELT.
6. Adjust rear belt deflection and rear wheel alignment. See
45°
BELT DEFLECTION ADJUSTMENT and WHEEL
ALIGNMENT under 1.15 REAR BELT DEFLECTION.
30°
7. Install belt guard. See 2.30 BELT GUARD AND DEBRIS
DEFLECTOR.
8. See Figure 6-79. Install sprocket cover (1). Secure with
3
two screws (2, 3). Note that long screw goes in top hole,
1
short screw in bottom hole. Do not tighten screws at this
1.
Transmission sprocket
time.
2.
Sprocket nut
9. Install exhaust pipe clamp bracket (4), washer (5) and
3.
Line scribed on nut and sprocket
screw (6). Tighten to 30-33 ft-lbs (40.7-44.8 Nm). Now
tighten screws (2, 3) to 80-120 in-lbs (9.0-13.6 Nm).
Figure 6-83. Transmission Sprocket Nut
Final Tightening Procedure
10. Install rear exhaust pipe and rear muffler. See
2.27
EXHAUST SYSTEM.
11. Open left side cover and install Maxi-Fuse. Close left
side cover. See 7.25 MAXI-FUSE.
6-50
2006 Sportster: Drive/Transmission
HOME
SPECIFICATIONS
7.1
IGNITION
BATTERY
All models
12 volt, 12 Ampere hours
Table 7-1. Spark Plugs
FUSES
ITEM
SPECIFICATION
Size
12 mm
Table 7-5. Amp Ratings
Gap
0.038-0.043 in. (0.97-1.09 mm)
Type
HD-6R12
ITEM
AMP RATING
Maxi-fuse
30
Battery
15
Table 7-2. Ignition Coil Resistance
Ignition
15
RESISTANCE
PRIMARY
SECONDARY
Lights
15
Accessory
15
All models
0.5-0.7 Ohms
5500-7500 Ohms
Instruments
15
CHARGING SYSTEM
Table 7-3. Alternator
ITEM
SPECIFICATION
AC voltage output
19-26 VAC per 1000 engine RPM
Stator coil resistance
0.2-0.4 Ohms
Table 7-4. Regulator
ITEM
SPECIFICATION
Voltage output @ 75˚F
14.3-14.7 VDC
Current @ 3600 RPM
22 Amps
2006 Sportster: Electrical
7-1
HOME
TORQUE VALUES
7.2
ITEM
TORQUE
NOTES
Ball head studs (front turn signals)
96-156 in-lbs
10.8-17.6 Nm
page 7-37
Battery strap screw
36-60 in-lbs
4.1-6.8 Nm
page 7-26
Battery tray mounting screw
96-156 in-lbs
10.9-17.6 Nm
page 7-5
Chrome horn acorn nut
60-180 in-lbs
7-20 Nm
page 7-56
Clutch lever handlebar clamp
108-132 in-lbs
12.2-14.9 Nm
page 7-52
Crank position sensor (CKP) screw
80-100 in-lbs
9.0-11.3 Nm
page 7-71
Decorative cover-to-handlebar riser screw
8-12 in-lbs
0.9-1.4 Nm
page 7-34
Fender mounting nut
132-216 in-lbs
14.9-24.4 Nm
page 7-39
Front turn signal Allen screw
96-120 in-lbs
10.8-13.5 Nm
page 7-38
Handlebar clamp
108-132 in-lbs
12.2-14.9 Nm
page 7-47
Horn bracket-to-horn stud nut, XL 1200C
80-100 in-lbs
9.0-11.3 Nm
Loctite 271 (red), page 7-56
Horn fastener (XL 883/XL 883L/XL 883C/XL
page 7-55
35-45 in-lbs
4.0-5.1 Nm
1200R)
ICM mounting stud
36-60 in-lbs
4.1-6.8 Nm
page 7-61
Ignition coil fasteners
24-72 in-lbs
2.7-8.1 Nm
page 7-14
Ignition control module (ICM) lock nut
12-15 in-lbs
1.4-1.7 Nm
page 7-11, 7-61
Ignition/light switch mounting screw
35-45 in-lbs
4.0-5.1 Nm
page 7-10
MAP sensor clip
25-35 in-lbs
2.8-3.9 Nm
page 7-8
Negative battery cable-to-crankcase screw
55-75 in-lbs
6.2-8.5 Nm
page 7-27
Negative battery terminal screw (10 mm)
40-50 in-lbs
4.5-5.7 Nm
page 7-26
Neutral indicator switch
36-60 in-lbs
4.0-6.8 Nm
page 7-75
Positive battery cable-to-starter post lock nut
60-85 in-lbs
6.8-9.6 Nm
page 7-26
Positive battery terminal screw (10 mm)
40-50 in-lbs
4.5-5.7 Nm
page 7-26
Rear brake hose clamp-to-
page 7-5
30-40 in-lbs
3.4-4.5 Nm
battery tray screw
Rear brake lamp switch screw
72-120 in-lbs
8.1-13.6 Nm
page 7-5
Rear master cylinder reservoir mounting screw
20-25 in-lbs
2.3-2.8 Nm
page 7-5, 7-41
Riser cover screw
8-12 in-lbs
0.9-1.4 Nm
page 7-38, 7-67
Rotor-to-sprocket screw
120-140 in-lbs
13.6-15.8 Nm
page 7-18
Speedometer bracket screw
12-18 ft-lbs
16.3-24.4 Nm
page 7-33
Speedometer/tachometer bracket screw
12-18 ft-lbs
16.3-24.4 Nm
page 7-33
Stator mounting screw
30-40 in-lbs
3.4-4.5 Nm
page 7-17
Stoplight switch to tee nut
84-120 in-lbs
9.5-13.6 Nm
page 7-41
Switch housing screws
35-45 in-lbs
4.0-5.1 Nm
page 7-47, 7-52
Tail lamp base to rear fender
45-48 in-lbs
5.1-5.4 Nm
page 7-35
Tail lamp lens
20-24 in-lbs
2.3-2.7 Nm
page 7-35, 7-36
Turn signal (rear) stud nuts
132-216 in-lbs
14.9-24.4 Nm
page 7-39
Vehicle speed sensor (VSS) screw
80-100 in-lbs
9.0-11.3 Nm
page 7-72
Voltage regulator mounting screw
30-60 in-lbs
3.4-6.8 Nm
page 7-20
7-2
2006 Sportster: Electrical
Большое спасибо!
Ваше мнение очень важно для нас.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст