Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 23
9.
Spray all machined surfaces with clean engine oil.
10. Inspect crankshaft/flywheel assembly. See
RIGHT CRANKCASE HALF
TOOL NAME
PART NUMBER
CRANKSHAFT (ROLLER) BEARING
DRIVER SHIM
HD-42720-4
CRANKSHAFT (ROLLER) BEARING
REMOVAL/INSTALL PILOT/DRIVER
HD-44065-1
CRANKSHAFT (ROLLER) BEARING
REMOVAL/INSTALL SUPPORT TUBE
HD-44065-4
TORQUE VALUE
FASTENER
4.5-7.9 Nm
40-70
in-lbs
Right main bearing retaining
screws
2.8-3.9 Nm
25-35
in-lbs
Piston jet screw
Chain Guide Screen
See
. Remove, clean and install screen (3).
Replace screen O-ring with each removal.
Main Bearing Removal
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner.
1.
See
. Remove two main bearing retaining
screws (5) from the cam compartment side.
2.
See
. Obtain CRANKSHAFT (ROLLER)
BEARING REMOVAL/INSTALL PILOT/DRIVER (Part
No.
HD-44065-1)
and
CRANKSHAFT
(ROLLER)
BEARING REMOVAL/INSTALL SUPPORT TUBE (Part
No. HD-44065-4).
3.
Place support tube (2) on press table with the REMOVAL
end up. Note that the support tube is stamped to provide
proper orientation.
4.
With the cam compartment facing downward, position
crankshaft bearing bore over support tube. Verify the
curved edges on pilot/driver (1) match the curved edges
of crankcase (4) or damage will result.
5.
Slide pilot/driver (1) through bearing into support tube.
6.
Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until bearing is free.
7.
Remove crankcase, pilot/driver and bearing from support
tube. Discard bearing.
2
5
1
4
3
sm02815
1. Crankshaft (roller) bearing
2. Right crankcase half
3. Chain guide screen and O-ring
4. Crankshaft bearing bore
5. Screw (2)
Figure 3-131. Right Main Bearing
4
3
1
5
2
1
sm02816
1. Pilot/driver
2. Support tube
3. Ram
4. Curved edges
5. Support tube REMOVAL end up
Figure 3-132. Right Main Bearing Removal
2013 Softail Service: Engine 3-87
Main Bearing Installation
1.
See
. Obtain CRANKSHAFT (ROLLER)
BEARING REMOVAL/INSTALL PILOT/DRIVER (Part
No. HD-44065-1), CRANKSHAFT (ROLLER) BEARING
DRIVER SHIM (Part No. HD-42720-4) and CRANKSHAFT
(ROLLER) BEARING REMOVAL/INSTALL SUPPORT
TUBE (Part No. HD-44065-4).
2.
Spread a thin film of clean H-D 20W50 engine oil on O.D.
of
new
bearing (4).
3.
Place support tube (2) on press table with the INSTALL
end up. The support tube is stamped to provide proper
orientation.
4.
Place SHIM (Part No. HD-42720-4) on support tube (2).
5.
With cam compartment side facing upward, position
crankshaft bearing bore over support tube. Lip on support
tube (5) must contact edge of crankcase as shown. This
allows curved portion of inboard crankcase to contact top
curved portion of support tube (2).
6.
Start the
new
bearing in bearing bore with the lettering
facing into the cam compartment (up).
7.
Slide pilot/driver (1) through bearing into support tube.
8.
Center pilot/driver under ram (3) of press. Apply pressure
to pilot/driver until resistance is felt and bearing is bot-
tomed on the support tube.
9.
Remove pilot/driver and crankcase half from support tube.
NOTES
•
Verify that the bearing is flush or slightly below the surface
of the crankcase. Never "pull" the bearing into position
using the retaining screws.
•
If new bearing fastener is not available, apply LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (blue) before installation.
10. See
. Install two
new
main bearing retaining
screws (5) from the cam compartment side. Tighten screws
to 40-70
in-lbs
(4.5-7.9 Nm).
Piston Jets Removal
1.
See
. Remove two screws (1) to free piston
jet (2) from crankcase.
2.
Remove O-ring (3) from groove in mounting flange of jet.
Discard O-ring.
Piston Jets Installation
1.
See
. Apply a very thin film of clean H-D
20W50 engine oil to
new
O-ring (3) for piston jet. Install
new
O-ring in groove of jet mounting flange.
2.
With jet pointed upward, start two screws (1) to secure
piston jet (2) to crankcase. Tighten to 25-35
in-lbs
(2.8-
3.9 Nm).
NOTE
If piston jet is being reused, apply LOCTITE 222 LOW
STRENGTH THREADLOCKER AND SEALANT (purple) to
threads of screws before installation.
1
2
5
6
5
4
3
1
sm02817
1. Pilot/driver
2. Support tube
3. Ram
4. Crankshaft (roller) bearing
5. Support tube lip
6. Support tube INSTALL end up
Figure 3-133. Right Crankshaft (Roller) Bearing Installation
1
2
3
sm02818
1. Screw (4)
2. Piston jet (2)
3. O-ring (2)
Figure 3-134. Piston Jets
3-88 2013 Softail Service: Engine
LEFT CRANKCASE HALF
TOOL NAME
PART NUMBER
CRANKCASE BEARING
REMOVER/INSTALLER
B-45655
CRANKCASE BEARING
REMOVER/INSTALLER BASE
HD-42720-5
Main Bearing Removal
NOTE
Never move or lift the crankcase by grasping the cylinder studs.
The crankcase is too heavy to be carried in this manner and
may be dropped.
Do not rotate left crankcase half in engine stand such that
flywheel sprocket shaft is facing up. The flywheel assembly
can fall out, resulting in parts damage or moderate injury.
(00552b)
1.
Hold flywheel assembly to prevent it from falling out of left
crankcase half. Rotate bottom end assembly in engine
stand so assembly is upright and flywheel shafts are
horizontal.
2.
Carefully slide flywheel assembly out of left crankcase and
place it in a clean safe place.
3.
Remove thrust washer from outboard side of crankcase
half by pulling it past oil seal. Set thrust washer aside for
inspection or reuse.
4.
Remove oil seal from crankcase bore. Discard oil seal.
5.
See
. Using a flat blade screwdriver, carefully
lift edge of bearing retaining ring up out of its groove in
crankcase.
6.
Slide screwdriver tip around edge of bearing, lifting
retaining ring up and out of groove. Do not damage lip of
groove in crankcase.
sm02523
Figure 3-135. Removing Retaining Ring
1
2
sm02307
1. Support tube
2. Pilot/driver
Figure 3-136. Left Main Bearing Remover and Installer
Tools
3
1
3
2
sm02524
1. Ram
2. Pilot/driver
3. Support tube ("A" end up)
Figure 3-137. Left Main Bearing Removal
NOTE
See
. If the ram of the press is wider than the head
of pilot/driver (2), a suitable press plug will be needed in order
to remove the main bearing.
7.
Obtain CRANKCASE BEARING REMOVER/INSTALLER
(Part
No.
B-45655)
and
CRANKCASE
BEARING
REMOVER/INSTALLER BASE (Part No. HD-42720-5).
8.
See
. Place support tube (3) on press table
with "A" end up. Note that support tube is stamped "A"
and "B" to provide proper orientation.
9.
With the outboard side of the left crankcase half facing
upward, position main bearing bore over support tube.
2013 Softail Service: Engine 3-89
10. Slide pilot/driver (2) through the main bearing into support
tube (3).
11. Center pilot/driver under ram (1) of press. Apply pressure
to pilot/driver until bearing is free.
12. Remove crankcase half, pilot/driver and bearing from
support tube. Discard bearing.
Main Bearing Installation
NOTES
•
Never move or lift the crankcase by grasping the cylinder
studs. The crankcase is too heavy to be carried in this
manner and may be dropped.
•
Always replace sprocket shaft bearing inner race whenever
left main bearing is replaced. See
DISASSEMBLY AND REPAIR, Sprocket Shaft Bearing
Inner Race
1.
See
. Obtain CRANKCASE BEARING
REMOVER/INSTALLER
(Part
No.
B-45655)
and
CRANKCASE BEARING REMOVER/INSTALLER BASE
(Part No. HD-42720-5).
1
3
4
2
3
sm02525
1. Ram
2. Pilot/driver
3. Support tube ("A" end up)
4. Main bearing
Figure 3-138. Left Main Bearing Installation
2.
See
. Place a thin film of clean engine oil on
outer diameter of
new
main bearing (4).
3.
Place support tube (3) on hydraulic press table with the
"A" end up.
4.
With the inboard side of the left crankcase half facing
upward, position main bearing bore over support tube.
5.
Start
new
main bearing in bearing bore, letter side down.
6.
Slide pilot/driver (2) through bearing into support tube.
7.
Apply pressure to pilot/driver until bearing is lightly bot-
tomed in main bearing bore.
8.
Remove crankcase half and pilot/driver from support tube.
9.
Install
new
retaining ring in bearing bore groove, being
careful not to damage edges of groove. Make sure
retaining ring is fully seated in groove.
NOTE
If retaining ring will not fit into groove, the bearing may not be
fully seated in the bore. Inspect bearing and bore. If necessary,
remove bearing, clean bore and install bearing. Then install
retaining ring.
SPROCKET SHAFT BEARING INNER RACE
TOOL NAME
PART NUMBER
ROBINAIR HEAT GUN
HD-25070
MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER
HD-34902-B
FLYWHEEL SUPPORT FIXTURE
HD-44358
WEDGE ATTACHMENT
HD-95637-46B
SPROCKET SHAFT BEARING
INSTALLER
HD-97225-55C
Removal
If reusing flywheel, remove bearing inner race and thrust
washer as follows:
1.
See
. Install brass jaws or shop towels around
teeth of vise to prevent damage to tool. Obtain FLYWHEEL
SUPPORT FIXTURE (Part No. HD-44358). Clamp tool in
vise with the round hole topside.
2.
Insert crankshaft end through hole resting flywheel
assembly on fixture. Slide knurled locating pin down slot
in tool to engage crank pin hole. Hand tighten locating pin.
3.
Slide hold-down clamp down slot to engage inboard side
of right flywheel half, and then hand tighten knurled nut at
bottom to secure. Repeat step to secure hold-down clamp
on opposite side of flywheel.
NOTE
For proper clamping force, hold-down clamp must not be tilted.
Rotate hex on outboard stud until clamp is level.
1
2
sm03852
1. Locating pin
2. Hold-down clamp
Figure 3-139. Flywheel Holding Fixture
3-90 2013 Softail Service: Engine
4.
Position WEDGE ATTACHMENT (Part No. HD-95637-
46B) on inboard side of thrust washer and turn hex nuts
an equal number of turns to draw halves of wedge
together.
Install wedge attachment only so far as necessary to
ensure positive contact with bearing inner race. Installing
tool with more contact than necessary will result in damage
to the flywheel (00500b)
5.
Obtain two 3/8-16 inch bolts 7-1/2 inches long (with flat
washers). Install flat washers on bolts. Obtain bridge and
forcing screw from MAINSHAFT BEARING INNER RACE
PULLER/INSTALLER (Part No. HD-34902-B). Also obtain
a suitable hardened washer to use between the puller
screw and the end of the shaft.
6.
Slide one bolt into channel on each side of bridge so that
flat washer is between bridge and bolt head. Thread bolts
into wedge attachment an equal number of turns.
7.
Sparingly apply graphite lubricant to threads of forcing
screw to prolong service life and verify smooth operation.
Start forcing screw into center hole of bridge.
NOTE
Failure to use hardened washer may result in damage to forcing
screw and/or sprocket shaft.
8.
Place hardened washer against end of sprocket shaft.
Thread forcing screw into bridge until the steel ball at the
end of the screw makes firm contact with hardened
washer.
Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)
9.
Using the ROBINAIR HEAT GUN (Part No. HD-25070),
uniformly heat the bearing inner race for about 30 seconds
using a circular motion.
NOTE
To assist removal without heat, apply a light penetrating oil to
shaft and leading edge of bearing inner race.
10. Turn forcing screw until thrust washer and bearing inner
race move approximately 1/8 in. (3.2 mm).
11. Turn hex nuts an equal number of turns to separate halves
of WEDGE ATTACHMENT (Part No. HD-95637-46B).
12. After bottoming thrust washer on shaft, reposition WEDGE
ATTACHMENT (Part No. HD-95637-46B) on inboard side
of bearing inner race. Turn hex nuts an equal number of
turns to draw halves of wedge together.
Install wedge attachment only so far as necessary to
ensure positive contact with bearing inner race. Installing
tool with more contact than necessary will result in damage
to the flywheel (00500b)
13. See
. Verify that the tool assembly is square,
so that the bearing inner race is not cocked during
removal.
14. Using the ROBINAIR HEAT GUN (Part No. HD-25070),
uniformly heat the bearing inner race for about 30 seconds
using a circular motion.
NOTE
To assist removal without heat, apply a light penetrating oil to
shaft and leading edge of bearing inner race.
15. Turn forcing screw until bearing inner race is pulled free
of sprocket shaft.
16. Remove thrust washer from sprocket shaft.
2
1
3
7
6
5
4
sm03853
1. Forcing screw
2. 3/8-16 in. bolt with flat washer
3. Bridge
4. Hardened washer
5. Wedge attachment
6. Bearing inner race
7. Sprocket shaft
Figure 3-140. Remove Inner Race from Sprocket Shaft
Installation
1.
Place
new
thrust washer over sprocket shaft.
2.
Place
new
bearing inner race on bench top. Using the
ROBINAIR HEAT GUN (Part No. HD-25070), uniformly
heat bearing inner race for about 60 seconds using a cir-
cular motion.
3.
Wearing suitable gloves to protect hands from burns, place
heated bearing inner race over sprocket shaft.
2013 Softail Service: Engine 3-91
Do not use heating devices with penetrating oil. Penet-
rating oil is flammable which could result in death or ser-
ious injury. (00375a)
NOTE
To assist installation without heat, apply a light penetrating oil
to shaft and leading edge of bearing inner race.
4.
See
. Obtain the SPROCKET SHAFT
BEARING
INSTALLER
(Part
No.
HD-97225-55C).
Assemble tool as described below.
a.
See
. Thread pilot adapter into sprocket
shaft.
b.
Thread pilot shaft onto pilot adapter.
c.
Slide long collar over pilot shaft until it contacts
bearing inner race.
d.
Slide short collar over pilot shaft until it contacts long
collar.
e.
Slide bearing and large flat washer over pilot shaft.
f.
Sparingly apply graphite lubricant to threads of pilot
shaft to prolong service life and verify smooth opera-
tion.
g.
See
. Thread handle onto pilot shaft.
5.
See
. Rotate handle of tool clockwise until
bearing inner race makes firm contact with thrust washer.
Verify that thrust washer cannot be rotated by hand.
6.
Remove handle, flat washer, bearing, short collar, long
collar, pilot shaft and pilot adapter from sprocket shaft.
sm03854
Figure 3-141. Sprocket Shaft Bearing Installer
sm03855
Figure 3-142. Thread Pilot Adapter into Sprocket Shaft
1
2
3
4
5
6
7
8
9
sm03856
1. Pilot adapter
2. Pilot shaft
3. Handle
4. Flat washer
5. Bearing
6. Short collar
7. Long collar
8. Inner race
9. Thrust washer
Figure 3-143. Press Inner Race onto Sprocket Shaft: Setup
3-92 2013 Softail Service: Engine
sm03857
Figure 3-144. Press Inner Race onto Sprocket Shaft:
Operation
CYLINDER STUDS
TORQUE VALUE
FASTENER
13.6-27.1 Nm
120-240
in-lbs
Cylinder stud
Removal
1.
Thread a nut onto cylinder stud.
2.
Thread a second nut onto stud until it contacts the first.
3.
Placing wrench on first nut installed, remove stud.
Installation
1.
Place a steel ball inside a head screw. Put the head screw
on the end of the cylinder stud without the collar.
2.
Start the stud in the cylinder deck with the collar side down.
Tighten using air gun until collar reaches crankcase.
3.
Hand tighten stud to 120-240
in-lbs
(13.6-27.1 Nm).
PIPE PLUGS AND OIL FITTINGS
TORQUE VALUE
FASTENER
13.6-19.0 Nm
120-168
in-lbs
Crankcase oil fittings
13.6-16.3 Nm
120-144
in-lbs
Crankcase pipe plugs
Removal/Installation
NOTE
See
for information on repla-
cing O-rings and retainers within oil tank fittings.
1.
See
. Remove parts.
a.
Turn hex on oil fittings (1, 2, 3) counterclockwise until
free.
b.
Turn pipe plugs (4, 5) counterclockwise until free.
2.
Apply LOCTITE 565 THREAD SEALANT to fitting threads.
3.
See
. Install parts.
a.
Turn hex on oil fittings (1, 2, 3) clockwise until snug.
Tighten to oil fittings to 120-168
in-lbs
(13.6-19.0
Nm).
b.
Install pipe plugs (4, 5). Tighten to 120-144
in-lbs
(13.6-16.3 Nm).
sm02823
Figure 3-145. Collar Side Down
3
1
2
4
5
sm02824
1. Oil return fitting
2. Oil feed fitting
3. Oil vent fitting
4. Pipe plug
5. Pipe plugs (2)
Figure 3-146. Oil Fittings and Pipe Plugs
2013 Softail Service: Engine 3-93
3.27
FLYWHEEL AND CONNECTING RODS
GENERAL
Symptoms
Flywheels that shift out of true at the crank pin generally exhibit
one of two symptoms: no oil pressure or vibration. This condi-
tion is also known as scissored flywheels.
No Oil Pressure
When the right side crankshaft shifts more than 0.015 in (0.381
mm), it can break the oil pump gerotors, resulting in a loss of
oil pressure.
If a very low or no oil pressure condition is confirmed, inspect
the oil pump and cam support plate. If the oil pump gerotors
are bound or damaged, the cause is likely from a contaminant
running through the pump or a shifted crankshaft. If this type
of damage is found, always replace the oil lines and clean all
debris
from
the
oil
pan
or
oil
tank.
See
for general diagnostics of low oil
pressure.
Vibration
Generally, left crankshaft runout must exceed 0.020 in. (0.508
mm) to be noticeable to the rider. It is much more likely that
vibration issues will be resolved by following the checklist in
.
If correct chassis set-up has been verified and other items in
have been eliminated, checking
left crankshaft runout is appropriate.
INSPECTION
NOTE
Do not attempt to straighten connecting rods. Straightening
rods will damage both the upper bushing and lower bearing.
1.
Replace the flywheel/connecting rod assembly if any of
the following conditions are noted:
a.
Connecting rods are bent or twisted.
b.
Connecting rods do not fall under their own weight or
are in a bind.
c.
Sprocket teeth are worn in an irregular pattern or
chipped.
d.
The crankshaft (roller) bearing inner races are
brinelled, burnt, scored, blued or damaged.
e.
The crankshaft runout exceeds specification.
NOTE
Bluing on connecting rods is part of the hardening process and
is considered a normal condition.
2.
Check connecting rod bearing clearance. Orient the
assembly as shown in
a.
Holding the shank of each rod just above the bearing
bore, pull up and down on the connecting rods.
b.
Any discernible up and down movement indicates
excessive lower bearing clearance. Replace the fly-
wheel/connecting rod assembly.
3.
Measure crankshaft runout if the crankshaft is suspected
of being out-of-true.
NOTE
If the flywheel, connecting rods or right side bearing inner race
need to be replaced, then replace the entire flywheel assembly.
sm02310
Figure 3-147. Connecting Rod Bearing Clearance
sm02311
Figure 3-148. Connecting Rod Side Play
MEASURING CRANKSHAFT RUNOUT
Crankshaft Installed
NOTES
•
Perform the following checks during engine disassembly
as a method to determine condition of crankshaft and
whether crankshaft is suitable for reuse. The checks can
3-94 2013 Softail Service: Engine
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 6-32. Transmission Gears and Shifter Forks
INSTALLATION
TORQUE VALUE
FASTENER
31.2-33.9 Nm
23-25 ft-lbs
Transmission bearing housing
screw
10.2-13.6 Nm
90-120
in-lbs
Transmission top cover
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
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 bearing housing
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.
5.
If equipped, place exhaust bracket into position. Install
bearing housing fasteners.
6.
See
. Tighten all bearing housing hardware in
the sequence shown to 23-25 ft-lbs (31.2-33.9 Nm).
7
4
1
6
8
5
3
2
sm03926
Figure 6-33. Bearing Housing Hardware Torque Sequence
7.
Install mainshaft bearing inner race. See
8.
See
. Install pushrod assembly (items 2-5) in
mainshaft hole. Secure with
new
retaining ring (1) if
removed.
NOTE
The two top side cover fasteners are shorter than the others.
9.
Install the clutch release cover, using a
new
gasket. See
10. Remove shifter cam pawl from top cover gasket surface
and place on shift cam. Install
new
transmission top cover
gasket. Install transmission top cover. Install top cover
fasteners and tighten 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
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. Install oil tank. See
.
17. Install exhaust system. See
6-22 2013 Softail 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
bearing
housing.
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 bearing housing
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.
2013 Softail Service: Transmission 6-23
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 6-34. Removing Main Drive Gear
2
1
3
4
sm03034
1. Main drive gear
2. Long bolt (2)
3. Wedge attachment
4. Press ram
Figure 6-35. 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 6-36. 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. Dry with compressed air.
NOTE
Never wash the transmission case and needle bearings with
solvent unless replacing the needle bearings. Normal cleaning
methods will wash dirt or other contaminants into the bearing
case (behind the needles) and will lead 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.
6-24 2013 Softail 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 replacing the main drive gear needle bearings and/or seal,
continue as follows. Otherwise, proceed to
.
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 6-37. Main Drive Gear Assembly
1
2
sm03038
1. Original retaining ring
2. Replacement retaining ring
Figure 6-38. 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 6-39. 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, Installation
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.
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)
2013 Softail Service: Transmission 6-25
7.
See
. Install
new
retaining rings (1).
8.
Install
new
O-ring (4) into groove in main drive gear.
sm03044
Figure 6-40. Pressing in Seal
sm02302
Figure 6-41. Installing Transmission Side Needle Bearing
in Main Driver Gear
INSTALLATION
TOOL NAME
PART NUMBER
INSTALLER CUP
HD-35316-12
CROSS PLATE
HD-35316-3A
8 IN. BOLT
HD-35316-4A
12 IN. BOLT
HD-35316-5
WASHER
HD-35316-7
BEARING DRIVER
HD-35316-8
INSTALLER
HD-47856-1
PILOT
HD-47856-2
ADAPTER
HD-47856-3
NUT
HD-47856-6
CROW'S FOOT WRENCH
HD-47856-7
Improper tightening of sprocket nut can cause drive
component damage. (00541b)
Installing Main Drive Gear Bearing
NOTE
CROSS PLATE (Part No. HD-35316-3A) will retrofit to earlier
transmissions. Note that one end of cross plate is stamped,
"UP 6 SPEED". Mount cross plate with this end pointing up for
6 speed transmissions.
1.
See
. Place CROSS PLATE (Part No. HD-
35316-3A) (2) on right side of transmission case as shown,
and secure with two screws (3). Position cross plate with
large bolt hole in cross plate aligned with main drive gear
bearing bore.
2.
Apply a light coat of graphite lubricant to the threads of 12
IN. BOLT (Part No. HD-35316-5) (1) and install through
cross plate and main drive gear bearing bore.
3.
At left side of case, place main drive gear bearing (4),
BEARING DRIVER (Part No. HD-35316-8) (5), BEARING
(6), FLAT WASHER (7) and NUT (8) over end of bolt.
4.
Tighten nut until main drive gear bearing bottoms against
lip cast into transmission case bearing bore.
6-26 2013 Softail Service: Transmission
1
2
8
7
4
3
6
5
sm03051
1. 12 in. bolt
2. Cross plate
3. Screw (2)
4. Main drive gear bearing
5. Bearing driver
6. Bearing
7. Flat washer
8. Nut
Figure 6-42. Installing Main Drive Gear Bearing (Typical)
Installing Main Drive Gear
NOTE
See
. Make sure new O-ring (4) is installed onto
main drive gear (3). Lubricate O-ring with SCREAMIN' EAGLE
ASSEMBLY LUBE before installing drive gear into transmission
case.
1.
See
. Apply a light coat of graphite lubricant
to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1)
and insert through WASHER (Part No. HD-35316-7) (2)
and main drive gear (3). Insert assembly into transmission
case, through main drive gear bearing.
2.
At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (5), BEARING (6), FLAT WASHER (7) and NUT
(8) over end of bolt.
3.
Tighten nut until main drive gear contacts main drive gear
bearing.
NOTE
See
. In next step, bearing retaining ring must be
installed with the flat side facing the bearing and the opening
in the ninety degree range shown.
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
new
retaining ring (2).
6
7
8
5
4
2
1
3
sm03052
1. 8 in. bolt
2. Washer
3. Main drive gear
4. O-ring
5. Installer cup
6. Bearing
7. Flat washer
8. Nut
Figure 6-43. Installing Main Drive Gear (Typical)
sm03053
Figure 6-44. Retaining Ring Opening
Installing Main Drive Gear Large Seal
1.
See
. From outside of crankcase, install 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 FORMULA+
TRANSMISSION AND PRIMARY CHAINCASE LUB-
RICANT.
2013 Softail Service: Transmission 6-27
3.
See
. Place seal over pilot with garter spring
facing bearing, and position seal squarely in end of
crankcase bore.
NOTE
ADAPTER (Part No. HD-47856-3) and main drive gear have
right-hand threads.
4.
See
. Thread ADAPTER (Part No. HD-47856-
3) onto end of main drive gear until it contacts main drive
gear.
1
2
sm03057
1. Pilot
2. Retaining ring
Figure 6-45. Install Pilot
sm03058
Figure 6-46. Place Main Drive Gear Seal Over Pilot
sm03059
Figure 6-47. Install Adapter
5.
See
. Slide INSTALLER (Part No. HD-47856-
1) (1) over adapter until cupped end of installer is flat
against seal.
6.
Thread NUT (Part No. HD-47856-6) (2) onto end of
adapter, until it tightens against installer.
7.
See
. Place CROW'S FOOT WRENCH (Part
No. HD-47856-7) (1) with 1/2 inch drive breaker bar (2)
on large nut. Place an adjustable wrench (3) on flats of
hex head cast into end of adapter.
8.
Holding adjustable wrench, tighten large nut with crow's
foot wrench until outer face of seal is flush with outer edge
of transmission bore.
NOTE
It is acceptable to recess seal as much as 0.030 in. (0.762 mm)
below outer edge of bore. Seal depth is controlled by tool.
9.
Remove nut, installer, adapter and pilot.
10. Install bearing housing and transmission components. See
6.6 TRANSMISSION ASSEMBLY, Installation
11. Install sprocket and drive belt. See
. Do not adjust belt at this time.
12. Install the bearing inner race on the transmission main-
shaft. See
6.8 TRANSMISSION CASE, Assembly
13. Install the primary chaincase housing. See
CHAINCASE HOUSING, Installation
.
14. Install the clutch assembly, primary chain, chain tensioner
assembly and compensating sprocket components See
5.4 DRIVE COMPONENTS, Installation
15. Install the primary chaincase cover. See
.
16. Adjust the drive belt. See
SPROCKETS, Adjusting Belt Deflection
17. Install exhaust system. See
or
SYSTEM, System: FLSTN, FLSTF/B, FLS, FXS
.
6-28 2013 Softail Service: Transmission
1
2
sm03061
1. Installer
2. Nut
Figure 6-48. Installer and Nut
1
3
2
sm03062
1. Crow's foot wrench
2. 1/2 in breaker bar
3. Adjustable wrench
Figure 6-49. Press Seal Into Crankcase
2013 Softail Service: Transmission 6-29
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