Harley Davidson 2008 Touring Models. Service Manual — page 24
2.
Inspect the three balls (2) and ball socket surfaces on
ramps (1, 3) for wear, pitting, surface breakdown and other
damage. Replace damaged parts.
3.
Check fit of the ramp coupling (4) on inner ramp (1).
Replace both parts if there is excessive wear.
4.
Inspect the retaining ring (6) for damage or distortion.
5.
Check clutch cable end for frayed or worn ends. Replace
cable if damaged or worn. Check cable fitting o-ring for
cuts, tears or signs of deterioration.
6.
Check the bore in the cover (5) where the ramps (1, 3)
are retained. There should be no wear that would cause
the ramps to cock, causing improper clutch adjustment.
1
6
7
4
8
5
2
3
sm03010
1.
Inner ramp
2.
Balls (3)
3.
Outer ramp
4.
Ramp coupling
5.
Clutch release cover
6.
Retaining ring
7.
Gasket
8.
Tab
Figure 7-6. Release Mechanism Assembly
ASSEMBLY AND INSTALLATION
NOTE
Replace cable fitting o-ring if damaged or deformed.
1.
See
. Screw clutch cable fitting (1) into clutch
release cover. Do not tighten at this time.
2.
. Place outer ramp (3) with ball socket side
up in clutch release cover. Be sure tab (8) is in clutch
release cover slot.
3.
Apply a multi-purpose grease to the balls and outer ramp
sockets. Place a ball in each of the outer ramp sockets.
4.
See
. Connect cable end to ramp coupling (3).
Install coupling on inner ramp (5) and place inner ramp
and coupling in position in clutch release cover.
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
Retaining ring opening (6) must be centered above the break
in the ribbing at bottom of the clutch release cover.
5.
Install retaining ring (4).
6.
Verify that two dowel pins are in place on transmission
side door flange. Place a new gasket on dowel pins.
NOTE
See
. Clutch release cover screws in positions (1)
and (6) are shorter than the others.
7.
. Install clutch release cover. Tighten screws
to 84-108 in-lbs (9.5-12.2 Nm) in sequence shown.
8.
Tighten clutch cable fitting to 90-120 in-lbs (10.2-13.6
Nm).
9.
Fill transmission to proper level with fresh transmission
fluid. See
1.10 TRANSMISSION LUBRICANT, Transmis-
sion Lubrication: Touring Models
.
10. Adjust clutch cable. See
.
11. Install exhaust system if removed. See
.
12. Install maxi-fuse.
7-6 2008 Touring Service: Transmission
7.5
TRANSMISSION ASSEMBLY
REMOVAL
NOTE
Leave the transmission case in the frame unless the case itself
requires replacement. For illustration purposes, some photo-
graphs may show the case removed. For information on case
removal see
.
1.
Remove exhaust system. See
.
2.
Remove primary chaincase cover, clutch assembly,
primary chain, compensating sprocket assembly and
primary chaincase. See
3.
Remove the bearing inner race from the transmission
mainshaft. See
6.4 PRIMARY CHAINCASE HOUSING,
.
4.
Remove the clutch release cover from the transmission
side door. See
7.4 CLUTCH RELEASE COVER, Removal
.
5.
See
. Remove oil slinger assembly from main-
shaft. Insert long rod through mainshaft bore and remove
push rod.
6.
Remove transmission top cover, leaving the cover gasket
in place.
7.
See
. Rotate the shifter pawl forward enough
to raise the free end and place shifter cam pawl on top
cover gasket.
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 7-7. Push Rod Assembly
2
1
sm03011
1.
Shifter pawl
2.
Top cover gasket surface
Figure 7-8. Set Shifter Pawl on Gasket
NOTES
•
Remove and install sprocket nut only while transmission
is in vehicle frame. Trying to remove and install sprocket
nut with transmission in transmission stand may cause
damage to transmission or stand.
•
The main drive gear bearing and retainer must be replaced
if the main drive gear is removed. The bearing will be
damaged during the removal procedure.
8.
If main drive gear is to be removed, see
.
9.
Cover mainshaft clutch hub splines with tape to prevent
the splines damaging the main drive gear bearings.
10. See
. Remove the transmission side door
mounting hardware. Remove exhaust bracket, if equipped.
NOTE
. Never attempt to remove side door by tapping
on shafts from opposite side. Tapping them with a hammer will
damage the side door bearings. If the side door sticks or binds
on the ring dowels, pry open using indents at each side of side
door.
11. Pry the side door loose and remove side door, mainshaft,
countershaft and shifter cam from transmission case as
an assembly. Discard gasket.
2008 Touring Service: Transmission 7-7
sm05040
Figure 7-9. Side Door Pry Point
2
2
2
1
sm03669
1.
Long screw (2)
2.
Short screw (6)
Figure 7-10. Side Door hardware
DISASSEMBLY
TOOL NAME
PART NUMBER
TRANSMISSION SHAFT RETAINING
RING PLIERS
J-5586A
Shifter Cam/Shifter Forks
1.
. With side door on end (shafts pointing
upward), remove shift fork shafts using easy-out screw
extractor (14) (non-flute design). Shafts have slight inter-
ference fit. Shafts can be reused, do not damage end of
shaft. Mark end of shaft so same end can be reinserted
during reassembly.
NOTE
Shifter shafts have a slight interference fit. Shifter shafts can
be reused, so avoid damaging end of shaft. Mark shafts so
they can be reinstalled in original position during assembly.
2.
Remove shift forks from dog rings.
3.
. Remove lock plate fasteners (3) from
lock plate (2). Discard fasteners.
4.
. Insert screwdriver and gently pry back
detent arm (4) to remove detent spring (3) tension from
shift cam (5). Remove shift cam.
5.
If servicing detent assembly, remove detent screw (2),
detent arm (4), sleeve and detent spring (3). Discard detent
screw.
NOTE
Although many transmission parts can be installed in either
direction, make sure used parts are installed in same direction
as when removed to prolong usable life.
6.
See
. Using dog rings, lock two gears in place.
Temporarily place transmission assembly into transmission
case.
7.
Remove mainshaft and countershaft locknuts.
8.
Remove transmission assembly from transmission case.
3
4
5
6
7
1
2
13
14
12
11
10
9
8
sm05070
1.
Mainshaft
2.
Countershaft
3.
Mainshaft 1st gear
4.
Mainshaft 2nd gear
5.
Mainshaft 3rd gear
6.
Mainshaft 4th gear
7.
Mainshaft 5th gear
8.
Countershaft 1st gear
9.
Countershaft 2nd gear
10. Countershaft 3rd gear
11. Countershaft 4th gear
12. Countershaft 5th gear
13. Countershaft 6th gear
14. Screw extractor
Figure 7-11. Gear Set
7-8 2008 Touring Service: Transmission
1
3
3
2
4
sm03600
1.
Side door
2.
Lock plate
3.
Lock plate fastener (2)
4.
Shift cam
Figure 7-12. Shift Drum
2
1
5
4
3
sm03601
1.
Screwdriver
2.
Detent fastener
3.
Detent spring
4.
Detent arm
5.
Shift cam
Figure 7-13. Detent Assembly
1
1
2
2
4
3
sm03670
1.
Retaining ring (2)
2.
Bearing (2)
3.
Mainshaft locknut
4.
Countershaft locknut
Figure 7-14. Side Door Locknuts
2008 Touring Service: Transmission 7-9
Mainshaft
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
As mainshaft 4th gear, 3rd gear, 2nd gear and 1st gear are an
integral part of the shaft, damage to any gear requires main-
shaft replacement.
1.
. Using TRANSMISSION SHAFT
RETAINING RING PLIERS (Part No. J-5586A), remove
retaining ring. Remove dog ring (3), guiding hub (2),
mainshaft 5th gear (4) and bearing.
NOTE
Do not press directly on the end of the mainshaft. Place a
spacer such as a washer between the end of the mainshaft
and the press ram.
2.
Place transmission assembly in arbor press and press
mainshaft out of side door bearings.
4
1
3
2
sm03599
1.
Retaining ring pliers
2.
Guiding hub
3.
Dog ring
4.
Mainshaft 5th gear
Figure 7-15. Mainshaft Retaining Ring
7-10 2008 Touring Service: Transmission
22
36
1
2
3
29
30
31
32
34
35
37
38
34
33
39
28
27
23
24
25
26
4
5
8
13
19
18
20
17
14
7
9
6
10
12
15
11
16
21
sm03019
27.
14.
1.
Mainshaft 2nd gear
Bearing
Spacer
2.
28.
15.
Countershaft 1st gear
Mainshaft 1st gear
Lock ring
16.
3.
29.
Securing segment (2)
Bearing
Mainshaft 5th gear
30.
17.
4.
Dog ring
Dog ring
Dog ring
5.
31.
18.
Lock ring
Guiding hub
Guiding hub
19.
6.
32.
Countershaft 4th gear
Securing segment (2)
Retaining ring
33.
20.
7.
Retaining ring
Bearing
Guiding hub
8.
34.
21.
Countershaft 2nd gear
Main drive gear bearing (2)
Countershaft 5th gear (part of
countershaft)
9.
35.
Bearing
Main drive gear
22.
36.
Countershaft 6th gear (part of
countershaft)
10.
O-ring
Lock ring
11.
37.
Securing segment (2)
Bearing spacer
23.
38.
Mainshaft
12.
Retaining ring
Internal spline washer
13.
39.
24.
Countershaft 3rd gear
Oil seal
Bearing
25. Mainshaft 4th gear
26. Mainshaft 3rd gear
Figure 7-16. Mainshaft and Countershaft Assembly
2008 Touring Service: Transmission 7-11
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
7.5 TRANSMISSION ASSEMBLY, Disassembly
,
Replacing Side Door Bearings for side door bearing
replacement.
3.
. Remove washer (1), countershaft 1st
gear (2) and bearing.
4.
. Remove countershaft 2nd gear lock ring.
5.
. Remove securing segments (1). Remove
dog ring (3), guiding hub (2), countershaft 2nd gear (4)
and bearing.
2
1
sm03020
1.
Washer
2.
Countershaft 1st gear
Figure 7-17. Countershaft 1st Gear
sm03021
Figure 7-18. Lock Ring
1
4
1
2
3
sm03022
1.
Securing segment
2.
Guiding hub
3.
Dog ring
4.
Countershaft 2nd gear
Figure 7-19. Securing Segment
6.
See
. Remove countershaft 3rd gear lock ring.
7.
See
. Remove securing segments (1), internal
spline washer (2), countershaft 3rd gear (3) and bearing.
8.
. Remove 4th gear lock ring (1), securing
segments, dog ring (3), guiding hub (2), and countershaft
4th gear (4) and bearing.
NOTE
As countershaft 5th gear and 6th gear are an integral part of
the shaft, damage to either gear requires countershaft
replacement.
7-12 2008 Touring Service: Transmission
sm03023
Figure 7-20. Third Gear Lock Ring
1
2
3
1
sm03024
1.
Securing segment
2.
Internal spline washer
3.
Countershaft 3rd gear
Figure 7-21. Countershaft Third Gear
4
2
3
1
sm03025
1.
4th gear lock ring
2.
Guiding hub
3.
Dog ring
4.
Countershaft 4th gear
Figure 7-22. Countershaft Assembly
Replacing 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 (2).
2.
Press the bearings out of the side door.
3
2
1
sm05071
1.
Retaining ring (2)
2.
Bearing (2)
3.
Side door
Figure 7-23. Side Door Bearings
2008 Touring Service: Transmission 7-13
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.
. 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 7-24. 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.
. Install beveled retaining ring (2) 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 clean transmission lubricant before install-
ation.
•
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 lock rings have a stepped face. The
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.
. Place countershaft 3rd gear lock ring
over securing segments.
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
7-14 2008 Touring Service: Transmission
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.
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.
sm03027
Figure 7-25. Installing Countershaft
Mainshaft
NOTES
•
Failure to press on inner bearing race while pressing
bearing on the shaft will damage the bearing.
•
. 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).
sm02860
Figure 7-26. 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 45-55 ft-lbs (61.0-74.6 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.
. 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).
9.
. 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
2008 Touring Service: Transmission 7-15
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 7-27. Detent Assembly
2
1
5
4
3
sm03601
1.
Screwdriver
2.
Detent fastener
3.
Detent spring
4.
Detent arm
5.
Shift cam
Figure 7-28. Detent Assembly
7-16 2008 Touring Service: Transmission
1
3
3
2
4
sm03600
1.
Side door
2.
Lock plate
3.
Lock plate fastener (2)
4.
Shift cam
Figure 7-29. 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 7-30. Shifter Forks and Shafts
2
10
5
4
1
7
6
3
8
9
sm03029
1.
Long shift shaft
2.
5th and 6th gear shifter fork
3.
5th gear
4.
Short shift shaft
5.
4th 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 7-31. 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.
. Tighten all side door hardware in the
sequence shown to 13-18 ft-lbs (17.6-24.4 Nm).
2008 Touring Service: Transmission 7-17
2
2
2
1
sm03669
1.
Long screw (2)
2.
Short screw (6)
Figure 7-32. Side Door hardware
1
5
7
2
4
8
6
3
sm05044
Figure 7-33. Side Door Torque Sequence
7.
Install mainshaft bearing inner race. See
.
8.
. 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 84-132 in-
lbs (9.5-14.9 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
6.2 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 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 7-34. Push Rod Assembly
7-18 2008 Touring Service: Transmission
7.6
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
NICE BEARING
RS-25100-200
NICE 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
6.4 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), NICE 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.
•
. 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 NICE 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.
2008 Touring Service: Transmission 7-19
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.
Nice bearing
7.
Flat washer
8.
Nut
Figure 7-35. Removing Main Drive Gear
2
1
3
4
sm03034
1.
Main drive gear
2.
Long bolt (2)
3.
Wedge attachment
4.
Press ram
Figure 7-36. 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.
Nice bearing
7.
Flat washer
8.
Nut
Figure 7-37. 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.
7-20 2008 Touring Service: Transmission
4.
Replace the sprocket if teeth are cracked or worn. See
6.6 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
7.7 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
•
. 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 7-38. Main Drive Gear Assembly
1
2
sm03038
1.
Original retaining ring
2.
Replacement retaining ring
Figure 7-39. 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 7-40. 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
7.6 MAIN DRIVE GEAR AND BEARING, Mainshaft
.
4.
. 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.
2008 Touring Service: Transmission 7-21
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