Harley Davidson 2018 softail models. Service manual — page 17
1. Remove all gasket material from the crankcase flanges.
2. Clean all parts in a non-volatile cleaning solution or
solvent.
WARNING
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)
3. Dry parts with moisture-free compressed air.
4. Verify that all oil holes are clean and open.
5. Check ring dowels for looseness, wear or damage.
Replace if necessary.
6. Use a file to carefully remove any nicks or burrs from
machined surfaces.
7. Clean out tapped holes and clean up damaged threads.
8. Check the top of the crankcase for flatness with a
straightedge and feeler gauge. Replace if warped.
9. Spray all machined surfaces with clean engine oil.
10. Inspect crankshaft/flywheel assembly. See Symptoms.
Special Tools
Description
Part Number
Qty.
CRANKSHAFT GUIDE
HD-42326-B
1
LEFT MAIN BEARING OIL SEAL
HD-52064
1
INSTALLATION TOOL
SPROCKET SHAFT BEARING
HD-97225-55C
1
INSTALLER
Consumables
Description
Part Number
Size
HARLEY-DAVIDSON HIGH
99650-02
56 ml (2 fl oz)
PERFORMANCE SEALANT - GRAY
SCREAMIN' EAGLE ASSEMBLY
11300002
118 ml (4 fl oz)
LUBE
1.
Position right crankcase with cam compartment facing
down.
2.
Install flywheel assembly.
a. Work a liberal amount of SCREAMIN' EAGLE
ASSEMBLY LUBE into both main bearings and
balancer bearings.
b. Slide crankshaft guide onto flywheel sprocket shaft.
Special Tool: CRANKSHAFT GUIDE (HD-42326-B)
c. Slide flywheel assembly into right crankcase half.
d. Remove crankshaft guide tool.
3.
NOTE
See Figure 1. When aligning timing marks match
dash to dash and circle to circle.
Timing marks may not align exactly. Align to the
closest tooth.
See Figure 1. Install balancers.
a. Rotate flywheel so crankpin is at BDC.
b. Install balancer while aligning timing marks (2).
c. Repeat with remaining balancer.
4.
Remove alignment tool.
a. Rotate gear teeth slightly with a screwdriver to unload
pressure on tool.
b. Remove tool.
5.
NOTE
The balancer shafts may splay away from the
crankshaft. Wiggle crankcase during installation to
help fully seat balancer shaft in bearing.
Mate crankcase halves.
a. Verify that both dowel pins are installed in split line
face of right case half.
b. See Figure 2. Apply a bead of sealant to specification
to the split line face of right crankcase half.
Length/Dimension/Distance: 1.52 mm (0.06 in)
HARLEY-DAVIDSON HIGH PERFORMANCE
SEALANT - GRAY (99650-02)
c. Place crankshaft guide over end of crankshaft until it
contacts shoulder on shaft.
Special Tool: CRANKSHAFT GUIDE (HD-42326-B)
d. Mate case halves. Keep crankcase splitline parallel as
left crankcase is lowered into place.
e. Wiggle crankcase during installation to help fully seat
balancer shafts in bearing.
f. Remove crankshaft guide.
6.
See Crankcase Torque Sequence. Install 14 crankcase
screws.
a. Finger-tighten each screw.
b. Tighten screws in sequence shown
Torque: 13.6 N·m (120 in-lbs) Crankcase screws,
first torque
c. Loosen, then following the same sequence, final
tighten.
Torque: 20.3-25.8 N·m (15-19 ft-lbs) Crankcase
screws, last torque
7.
Rotate crankcase assembly so sprocket shaft is pointing
straight up.
8.
Install thrust washer on sprocket shaft with "THIS SIDE
OUT" facing out (and the chamfer inboard). If using
original part without markings, position to preserve
existing wear pattern.
9.
See Figure 3. Install new sprocket shaft oil seal using
components from the following tools.
Special Tool: SPROCKET SHAFT BEARING
INSTALLER (HD-97225-55C)
Special Tool: LEFT MAIN BEARING OIL SEAL
INSTALLATION TOOL (HD-52064)
a. Verify that lip garter spring is in place on both sides of
oil seal.
b. Install sprocket shaft spacer.
c. Install oil seal.
10. Rotate crankcase so that cam compartment is facing up.
11. Apply a liberal amount of lube to the main bearing. Rotate
flywheel assembly to distribute lube.
SCREAMIN' EAGLE ASSEMBLY LUBE (11300002)
1
Balancer gears
2
Timing marks
3
Flywheel gear
Figure 1. Balancer Timing Marks
Figure 2. Sealant
Figure 3. Sprocket Shaft Oil Seal Installer
Special Tools
Description
Part Number
Qty.
MAIN BEARING REMOVER AND
HD-52071
1
INSTALLER
Consumables
Description
Part Number
Size
LOCTITE 222 LOW STRENGTH
99811-97
6 ml (¼ fl oz)
THREADLOCKER (PURPLE)
Remove Main Bearing
NOTE
Never move or lift crankcase by grasping cylinder studs.
1. See Figure 1. Remove bearing using MAIN BEARING REMOVER AND INSTALLER (Part
Number:HD-52071).
a. Press bearing from cam side into flywheel side of crankcase.
2. Discard bearing.
1
Main bearing arbor
2
Bearing support
Figure 1. Remove Right Main Bearing
Install Main Bearing
See Figure 2. Install bearing using MAIN BEARING REMOVER AND INSTALLER (Part Number:HD-52071).
a. Place crankcase with flywheel side facing up on main bearing support (3).
b. Spread clean engine oil on OD of new bearing.
c. Place bearing on bearing bore with the lettering facing up.
d. Place main bearing installer (2) with side marked RIGHT against bearing.
e. Place main bearing arbor (1) through main bearing installer and bearing into bearing support.
f. Press until main bearing installer contacts machined surface.
g. Check installed depth. Refer to Table 1.
1
Main bearing arbor
2
Main bearing installer
3
Bearing support
4
Press ram
5
Main bearing
Figure 2. Right Main Bearing Installation
Table 1. Right Crankcase Bearing Installed Depth
BEARING LOCATION
DEPTH FROM SPLIT LINE
Right side main
54.86-55.37 mm (2.160-2.180 in)
Right side balancer
52.58-53.09 mm (2.070-2.090 in)
Remove Piston Jets
1. See Figure 3. Remove two screws (3) to free piston jet (2) from crankcase.
2. Discard gasket (1).
1
Gasket (2)
2
Piston jet (2)
3
Screw (2 each jet)
Figure 3. Piston Jets
Install Piston Jets
1. See Figure 3. Install new gasket (1).
2. With jet pointed up, secure piston jet (2) with two screws
(3).
a. If piston jet is being reused, apply threadlocker to
screws.
LOCTITE 222 LOW STRENGTH
THREADLOCKER (PURPLE) (99811-97)
b. Tighten to 2.8-3.9 N·m (25-35 in-lbs).
Special Tools
Description
Part Number
Qty.
MAIN BEARING ARBOR
HD-52071-2
1
MAIN BEARING INSTALLER
HD-52071-3
1
BEARING SUPPORT
HD-52071-4
1
Remove Main Bearing
CAUTION
Do not rotate crankcase half in engine stand when flywheel is installed. The flywheel assembly can fall out,
resulting in parts damage or moderate injury. (00552c)
NOTE
Never move or lift crankcase by grasping cylinder studs.
Always replace sprocket shaft bearing inner race whenever left main bearing is replaced. See Sprocket Shaft
Bearing Inner Race.
1. Remove thrust washer from outboard side of crankcase half by pulling it past oil seal. Set thrust washer aside
for inspection or reuse.
2. Remove oil seal.
3. Remove bearing using MAIN BEARING ARBOR (Part Number:HD-52071-2) and BEARING SUPPORT (Part
Number:HD-52071-4).
a. See Figure 1. Remove bearing retaining ring.
b. See Figure 2. Press bearing from stator side into flywheel side of crankcase.
4. Discard bearing.
Figure 1. Remove Retaining Ring
1
Main bearing arbor
2
Bearing support
Figure 2. Remove Left Main Bearing
Install Main Bearing
NOTE
Alternator stator may be left installed when main bearing press adapter is used.
1. See Figure 3. Install bearing using MAIN BEARING INSTALLER (Part Number:HD-52071-3), MAIN
BEARING ARBOR (Part Number:HD-52071-2) and BEARING SUPPORT (Part Number:HD-52071-4).
a. Place main bearing press adapter (3) on bearing support (4).
b. Place crankcase on main bearing press adapter (3) with flywheel side side facing up.
c. Spread clean engine oil on OD of new bearing.
d. Place bearing on bearing bore with lettering facing up.
e. Place main bearing installer (2) with side marked LEFT against the bearing.
f. Place main bearing arbor (1) through main bearing installer (2) and bearing into main bearing press
adapter (3) and bearing support (4).
g. Press until main bearing installer contacts machined surface.
2. Install new retaining ring in bearing bore groove. Make sure retaining ring is fully seated in groove.
1
Main bearing arbor
2
Main bearing installer
3
Main bearing press adapter
4
Bearing support
Figure 3. Install Left Main Bearing
Special Tools
Description
Part Number
Qty.
ROBINAIR HEAT GUN
HD-25070
1
BIG-TWIN MAINSHAFT PRIMARY
HD-34902-B
1
BEARING RACE REMOVER AND
INSTALLER
FLYWHEEL SUPPORT FIXTURE
HD-44358
1
WEDGE ATTACHMENT
HD-95637-46B
1
SPROCKET SHAFT BEARING
HD-97225-55C
1
INSTALLER
Remove
NOTE
For proper clamping force, hold-down clamp must not be tilted. Rotate hex on outboard stud until clamp is level.
1. See Figure 1. Secure flywheel assembly in FLYWHEEL SUPPORT FIXTURE (Part Number:HD-44358).
a. Secure fixture in soft-jawed vise with the round hole topside.
b. Insert crankshaft end through hole, resting flywheel assembly on fixture.
c. Engage knurled locating pin in crank pin hole.
d. Hand-tighten locating pin.
e. Secure flywheel with hold-down clamps (2).
1
Locating pin
2
Hold-down clamp
Figure 1. Flywheel Holding Fixture
NOTICE
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)
1. See Figure 2. Install pulling tool.
a. Position WEDGE ATTACHMENT (Part
Number:HD-95637-46B) (5) on inboard side of
thrust washer.
b. Draw wedge halves together evenly.
c. Secure the bridge and forcing screw from BIG-TWIN
MAINSHAFT PRIMARY BEARING RACE
REMOVER AND INSTALLER (Part
Number:HD-34902-B) to the wedge attachment with
flat washers and two 3/8-16 x 7-1/2 in bolts.
d. Place hardened washer between end of sprocket
shaft and the end of the forcing screw.
2. Uniformly heat the bearing inner race for about 30
seconds using the ROBINAIR HEAT GUN (Part
Number:HD-25070).
NOTE
To assist removal without heat, apply a light
penetrating oil to shaft and leading edge of bearing
inner race.
WARNING
Do not use heating devices with penetrating oil.
Penetrating oil is flammable which could result in
death or serious injury. (00375a)
3. See Figure 2. Remove bearing race.
a. Turn forcing screw until thrust washer and bearing
inner race move approximately 3.2 mm (0.125 in).
b. Reposition WEDGE ATTACHMENT (Part
Number:HD-95637-46B) to pull on bearing inner
race only.
c. Verify that the tool assembly is square.
d. Heat the bearing inner race for about 30 seconds.
e. Turn forcing screw until bearing inner race is free of
sprocket shaft.
f. Remove thrust washer from sprocket shaft.
1
Forcing screw
2
3/8-16 bolt with flat washer
3
Bridge
4
Hardened washer
5
Wedge attachment
6
Bearing inner race
7
Sprocket shaft
Figure 2. Remove Inner Race from Sprocket Shaft
Install
1. Place new thrust washer over sprocket shaft.
2. Uniformly heat new bearing for about 60 seconds using
the ROBINAIR HEAT GUN (Part Number:HD-25070).
3. Drop heated bearing inner race over sprocket shaft.
NOTE
To assist installation without heat, apply a light
penetrating oil to shaft and leading edge of bearing
inner race.
WARNING
Do not use heating devices with penetrating oil.
Penetrating oil is flammable which could result in
death or serious injury. (00375a)
4. See Figure 3. Seat the bearing race using SPROCKET
SHAFT BEARING INSTALLER (Part Number:HD-
97225-55C). Follow instructions supplied with tool.
5. Verify that thrust washer cannot be rotated by hand.
Figure 3. Press Inner Race onto Sprocket Shaft: Operation
Remove
1. Tighten two nuts together on threads of stud.
2. Place wrench on lower nut. Turn to remove stud.
Install
1. Place a steel ball inside a cylinder head screw.
2. Put the head screw on the long end of the cylinder stud.
3. Install stud using air gun until collar reaches crankcase.
4. Tighten to 13.6-27.1 N·m (120-240 in-lbs).
Remove
See Figure 1. Turn pipe plug or oil check valve counterclockwise to remove.
Install
1. See Figure 1. Install tapered plug (1).
a. Apply LOCTITE 565 THREAD SEALANT to threads.
Torque: 13.6-16.3 N·m (120-144 in-lbs)
Crankcase tapered plugs
2. Install oil check valve (2) or plug with O-ring (3).
a. Install new O-ring.
b. Tighten.
Torque: 24.4-29.8 N·m (18-22 ft-lbs) Crankcase oil
check valve or plug with O-ring
1
Tapered plug (5)
2
Oil check valve
3
Plug with O-ring
Figure 1. Crankcase Pipe Plugs
1. Install oil pump. See Prepare.
2. Install cam compartment components and cam cover. See
Prepare.
3. Install pistons. See Prepare.
4. Install cylinders. See Prepare.
5. Install cylinder heads. See Prepare.
6. Install pushrods, lifters and covers. See Prepare.
7. Install rocker arms. See Prepare.
8. Install lower rocker covers. See Prepare.
9. Install breathers. See Prepare.
10. Install upper rocker covers. See Prepare.
11. Install spark plugs. See Prepare.
12. Install engine. See Prepare.
Overview
Flywheels that shift out of true at the crank pin generally exhibit one of two symptoms: no oil pressure or vibration. This
condition is also known as scissored flywheels.
No Oil Pressure
When the crankshaft shifts more than 0.381 mm (0.015 in), it can break the oil pump gerotors. This causes a loss of oil
pressure.
If a 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 entire lubrication system. See
Engine for general diagnostics of low oil pressure.
Vibration
Generally, left crankshaft runout must exceed 0.508 mm (0.020 in) to be noticeable to the rider. It is much more likely
that vibration issues are resolved by following the checklist in Engine.
If correct chassis set-up has been verified and other items in Engine have been eliminated, checking left crankshaft
runout is appropriate.
1. Remove engine. See Prepare.
2.
NOTE
Abrasive particles can damage machined surfaces or
plug oil passageways. Clean parts before
disassembly to prevent component damage.
Use low-pressure compressed air to clean exterior
surfaces of engine.
3. Remove spark plugs. See Prepare.
4. Remove upper rocker covers. See Prepare.
5. Remove breathers. See Prepare.
6. Remove lower rocker covers. See Prepare.
7. Remove rocker arms. See Prepare.
8. Remove pushrods, lifters and covers. See Prepare.
9. Remove cylinder heads. See Prepare.
10. Remove cylinders. See Prepare.
11. Remove pistons. See Prepare.
12. Remove cam cover and cam compartment components.
See Prepare.
13. Remove oil pump. See Prepare.
14. Separate crankcase and remove flywheel and connecting
rods. See Prepare.
NOTE
For measure crankshaft runout procedure, see Typical Symptoms.
NOTE
Do not attempt to straighten connecting rods. Straightening rods damage both the upper bushing and lower
bearing.
Connecting rod bearing failures generally exhibit noise and secondary damage in the form of steel debris
circulating throughout the engine. Closely scrutinize the connecting rod bearing if any of the following are evident:
Rod knock noise
Steel debris in oil filter
Piston skirt scoring / scuffing
Wear of the oil pump scavenge rotor and housing
Piston to valve contact
Damage to the flywheel pinion journal
1. Replace the flywheel/connecting rod assembly if any of the following conditions are noted:
a. Bent or twisted connecting rods
b. Sprocket teeth are worn in an irregular pattern or chipped
c. The crankshaft (roller) bearing inner races are brinelled, burnt, scored, blued or damaged
d. Crankshaft runout exceeds specification
NOTE
Bluing on connecting rods is part of the hardening process and is considered a normal condition.
NOTE
In some cases the connecting rods will not fall under their own weight due to as-designed bearing preload. flywheels
should NOT be replaced if the rods can be rotated with light finger pressure.
2. Check connecting rod bearing clearance. Place the assembly as shown in Figure 1 .
a. Rotate each connecting rod around crankpin feeling for smooth operation.
b. Holding the shank of each rod just above the bearing bore, pull up and down on the connecting rods.
c. Any up and down movement indicates excessive lower bearing clearance. Replace the flywheel/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 require replacement, replace the entire flywheel
assembly.
Figure 1. Connecting Rod Bearing Clearance
1. Install flywheel and connecting rods and assemble
crankcase. See Prepare.
2. Install oil pump. See Prepare.
3. Install cam compartment components and cam cover. See
Prepare.
4. Install pistons. See Prepare.
5. Install cylinders. See Prepare.
6. Install cylinder heads. See Prepare.
7. Install pushrods, lifters and covers. See Prepare.
8. Install rocker arms. See Prepare.
9. Install lower rocker covers. See Prepare.
10. Install breathers. See Prepare.
11. Install upper rocker covers. See Prepare.
12. Install spark plugs. See Prepare.
13. Install engine. See Prepare.
1. Position motorcycle on a lift.
2. Drain engine oil. See Check Engine Oil Level.
3. Drain transmission lubricant. See Check Transmission Lubricant.
1. Remove the engine oil fill plug/dipstick.
2. See Unresolved graphic link. Remove oil pan.
a. Remove 10 screws (3).
b. Remove oil pan (2).
c. Discard oil pan gasket (1).
NOTE
Debris that remains in the pan can cause a repeat failure. Install a new oil pan if necessary.
3. Thoroughly inspect and clean the oil pan.
1
Gasket
2
Oil pan
3
Screws (14)
Figure 1. Oil Pan Assembly
Consumables
Description
Part Number
Size
LOCTITE 243 MEDIUM STRENGTH
99642-97
6 ml (¼ fl oz)
THREADLOCKER AND SEALANT
(BLUE)
1. Clean and examine all flange surfaces.
2. Clean engine oil and transmission lubricant drain plugs.
a.
Replace O-rings as required.
3. Install transmission drain plug and O-ring. Tighten.
Torque: 19-28.5 N·m (14-21 ft-lbs) Transmission drain
plug
4. Install engine oil drain plug and O-ring. Tighten. Torque:
19-28.5 N·m (14-21 ft-lbs) Engine oil drain plug
5. Install oil pan.
a. Apply a thin coat of HYLOMAR GASKET AND
THREAD SEALANT to oil pan flange.
b. Apply threadlocker to used oil pan screws. LOCTITE
243 MEDIUM STRENGTH THREADLOCKER AND
SEALANT (BLUE) (99642-97)
c. Place new gasket (1) on oil pan flange. Allow sealer
to dry until tacky.
d. Position oil pan with gasket on bottom of
transmission.
e. Loosely install fasteners (3).
f. Verify that the gasket is properly positioned. Tighten
following sequence shown.
Torque: 14.9-17.6 N·m (132-156 in-lbs) Oil pan
fasteners
Figure 1. Oil Pan Tightening Sequence
1. Add fluids.
a. Add transmission lubricant. See Check
Transmission Lubricant.
b. Install new engine oil filter.
c. Fill engine oil. See Check Engine Oil Level.
FASTENER
TORQUE VALUE
NOTES
Battery ground cable to transmission
7.5-12.9 N·m
5.15 TRANSMISSION CASE, Install
(66-114 in-lbs)
Clutch cable fitting
10.2-13.6 N·m
5.6 CLUTCH RELEASE COVER,
(90-120 in-lbs)
Install
Clutch hub mainshaft nut
94.9-108.5
5.8 DRIVE COMPONENTS, Install
N·m (70-80 ft-
lbs)
Clutch release cover screws
14.9-17.6 N·m
5.6 CLUTCH RELEASE COVER,
(132-156 in-lbs)
Install
Compensating sprocket bolt, final
237.3 N·m
5.8 DRIVE COMPONENTS, Install
torque
(175 ft-lbs)
Compensating sprocket bolt, first
135.6 N·m
5.8 DRIVE COMPONENTS, Install
torque
(100 ft-lbs)
Loosen then final tighten
Drive belt slot spacer screw, final
88-95 N·m
5.4 DRIVE BELT, Install
torque
(65-70 ft-lbs)
Drive belt slot spacer screw, first
68-75 N·m
5.4 DRIVE BELT, Install
torque
(50-55 ft-lbs)
Engine oil fill spout screw.
11.3-13.6 N·m
5.11 ENGINE OIL FILL SPOUT,
(100-120 in-lbs)
Install
Foot shift lever pinch screw,
12.2-16.3 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
front-mount
(9-12 ft-lbs)
Lever, Front
Front-Mount Foot shift lever pinch
12.2-16.3 N·m
5.5 SHIFTER LINKAGE, Foot Shift
screw
(108-144 in-lbs)
Lever
Mid-Mount Foot shift lever pinch
32.5-38 N·m
5.5 SHIFTER LINKAGE, Foot Shift
screw
(24-28 ft-lbs)
Lever
Oil return tube screw
11.3-13.6 N·m
5.15 TRANSMISSION CASE,
(100-120 in-lbs)
Assemble
Primary chain tensioner fasteners
28.5-32.6 N·m
5.8 DRIVE COMPONENTS, Install
(21-24 ft-lbs)
Primary chaincase sealing screws
35.3-38 N·m
5.10 PRIMARY CHAINCASE
(26-28 ft-lbs)
HOUSING, Install
Primary cover screws
16.3-17.6 N·m
5.7 PRIMARY CHAINCASE COVER,
(144-156 in-lbs)
Install
See sequence in the procedure
Rear fork pivot shaft nut, final torque
209-230 N·m
5.4 DRIVE BELT, Install
(154-170 ft-lbs)
Rear fork pivot shaft nut, first torque
34-41 N·m
5.4 DRIVE BELT, Install
(25-30 ft-lbs)
Rear fork pivot shaft nut, second
0.1-5.4 N·m
5.4 DRIVE BELT, Install
torque
(1-48 in-lbs)
Rear fork pivot shaft nut, third torque
209-230 N·m
5.4 DRIVE BELT, Install
(154-170 ft-lbs)
Rear fork pivot shaft pinch bolt
24-27 N·m
5.4 DRIVE BELT, Install
(18-20 ft-lbs)
Shift drum detent screw
13.6-17 N·m
5.13 TRANSMISSION, Assemble
(120-150 in-lbs)
Shift drum detent screw
13.6-17 N·m
5.13 TRANSMISSION, Assemble
(120-150 in-lbs)
Shift drum lock plate screws
6.4-7.1 N·m
5.13 TRANSMISSION, Assemble
(57-63 in-lbs)
Shift drum lock plate screws
6.4-7.1 N·m
5.13 TRANSMISSION, Assemble
(57-63 in-lbs)
Shifter pawl centering screw
24.4-31.2 N·m
5.15 TRANSMISSION CASE,
(18-23 ft-lbs)
Assemble
Shifter peg screw
10.9-16.3 N·m
5.5 SHIFTER LINKAGE, Foot Shift
(96-144 in-lbs)
Lever
Shifter rod jamnut
9.5-14.9 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
(84-132 in-lbs)
Shifter rod lever pinch screw, mid-
24.4-29.8 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
mount
(18-22 ft-lbs)
Lever, Front
Shifter rod lever pinch screw,
24.4-29.8 N·m
5.15 TRANSMISSION CASE,
transmission lever
(18-22 ft-lbs)
Assemble
Shifter rod to front shifter rod lever,
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
front foot control
(120-168 in-lbs)
Shifter rod to rear shifter rod lever,
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
front foot control
(120-168 in-lbs)
Shifter rod to shifter rod lever
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
(120-168 in-lbs)
Shifter rod to shifter rod lever, front-
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
mount
(120-168 in-lbs)
Lever, Front
Shifter rod to shifter rod lever, mid-
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
mount
(120-168 in-lbs)
Lever, Front
Shifter rod to shifter rod lever, mid-
13.6-19 N·m
5.5 SHIFTER LINKAGE, Shifter Rod
mount control
(120-168 in-lbs)
Transmission bearing housing
29.8-33.9 N·m
5.13 TRANSMISSION, Install
screws
(22-25 ft-lbs)
Transmission mainshaft/countershaft
115.3-128.8 N·m
5.13 TRANSMISSION, Assemble
locknuts
(85-95 ft-lbs)
Transmission mounting bolts, final
46.1-52.9 N·m
5.15 TRANSMISSION CASE, Install
torque
(34-39 ft-lbs)
Transmission mounting bolts, initial
20.3 N·m
5.15 TRANSMISSION CASE, Install
torque
(15 ft-lbs)
Transmission sprocket lockplate
10.2-13.6 N·m
5.12 TRANSMISSION SPROCKET,
screws
(90-120 in-lbs)
Install
Lock patch, use 3-5 times
Transmission sprocket nut, final
35-40°
5.12 TRANSMISSION SPROCKET,
torque
(35-40°)
Install
Do not loosen to align lockplate
screws.
Transmission sprocket nut, first
135.6 N·m
5.12 TRANSMISSION SPROCKET,
torque
(100 ft-lbs)
Install
Apply LOCTITE 271 HIGH
STRENGTH THREADLOCKER (red)
to last few threads. Loosen one full
turn after first torque.
Transmission sprocket nut, second
47.5 N·m
5.12 TRANSMISSION SPROCKET,
torque
(35 ft-lbs)
Install
plus 35-40 degrees
Transmission top cover
14.9-17.6 N·m
5.13 TRANSMISSION, Install
(132-156 in-lbs)
FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT and SCREAMIN' EAGLE SYN3 FULL
SYNTHETIC MOTORCYCLE LUBRICANT 20W50 are both acceptable lubricants.
Table 1. Primary Chaincase Lubricant
AMOUNT*
DRY FILL**
WET FILL***
OZ
L
OZ
L
Wide Primary
46
1.36
42
1.24
Narrow Primary
40
1.18
36
1.06
* Amount is approximate. Fill to bottom of pressure plate OD with vehicle upright.
** Cover was removed and installed.
*** Lubricant was drained through the drain plug only.
Table 2. Sprocket Teeth
DRIVE
ITEM
NUMBER OF TEETH
Primary
Engine
34
Clutch
46
Final
Transmission
32
Rear wheel
66
Table 3. Overall Drive Ratios
GEAR
RATIO
First
9.311
Second
6.454
Third
4.793
Fourth
3.882
Fifth
3.307
Sixth
2.790
NOTE
Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.
Table 1. Transmission Specifications
TRANSMISSION
DATA
Type
6-speed forward constant mesh
FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT
Part No. 99851-05 (qt)
SYN3 20W50 Oil
Part No. 99824-03/00QT (qt)
Capacity (dry; approximate)
0.95 L (32 fl oz)
Table 2. Transmission Gear Ratios
GEAR
GEAR RATIO
First (low)
3.34
Second
2.31
Third
1.72
Fourth
1.39
Fifth
1.19
Sixth (high)
1.00
NOTE
Final gear ratios indicate the number of mainshaft revolutions required to drive the output sprocket one revolution.
Table 1. Main Drive Gear Specifications
MAIN DRIVE GEAR (SIXTH)
IN
MM
Bearing fit in transmission case (loose)
0.0003-0.0017
0.0076-0.043
Fit in bearing (press-fit)
0.001-0.003
0.025-0.076
End play: Two row bearing
none
none
End play: Single row bearing
0.000-0.012
0.000-0.305
Table 2. Mainshaft Tolerance Specifications
MAINSHAFT TOLERANCE
IN
MM
Mainshaft runout
0.000-0.003
0.00-0.08
Mainshaft end play
none
none
Fifth gear end play (axial)
0.002-0.026
0.05-0.66
Fifth gear clearance (radial)
0.0004-0.0020
0.009-0.052
Main drive gear (sixth) fit
0.0009-0.0022
0.023-0.056
Table 3. Countershaft Tolerance Specifications
COUNTERSHAFT
IN
MM
TOLERANCE
Countershaft runout
0.000-0.003
0.00-0.08
Countershaft end play
0.001-0.003
0.025-0.08
First gear end play (axial)
0.001-0.023
0.03-0.58
First gear clearance (radial)
0.0004-0.0020
0.010-0.052
Second gear end play (axial)
0.001-0.40
0.03-1.02
Second gear clearance (radial)
0.0004-0.0020
0.010-0.052
Third gear end play (axial)
0.001-0.042
0.03-1.07
Third gear clearance (radial)
0.0004-0.0020
0.010-0.052
Fourth gear end play (axial)
0.001-0.028
0.03-0.71
Fourth gear clearance (radial)
0.0004-0.0020
0.010-0.052
Table 4. Shifter Dog Clearance Specifications
SHIFTER DOG
IN
MM
First
0.013-0.121
0.33-3.07
Second
0.016-0.138
0.41-3.51
Third
0.010-0.125
0.25-3.17
Fourth
0.018-0.129
0.46-3.28
Fifth
0.007-0.117
0.18-2.97
Sixth
0.022-0.131
0.56-3.33
Table 5. Bearing Housing Bearing Specifications
BEARING HOUSING BEARING
IN
MM
Fit in bearing housing (tight)
0.0001-0.0014
0.0025-0.0356
Fit on countershaft (tight)
-0.0004
-0.010
Fit on countershaft (loose)
+0.0012
+0.030
Fit on mainshaft (tight)
-0.0004
-0.010
Fit on mainshaft (loose)
+0.0012
+0.030
Table 6. Shifter Fork Specifications
SHIFTER FORKS
IN
MM
Shifter fork to cam groove end play
0.004-0.012
0.102-0.305
Shifter fork to dog ring end play
0.004-0.016
0.102-0.4060
First and second gear shift fork pad thickness wear limit
0.258
6.55
Third and fourth gear shift fork pad thickness wear limit
0.198
5.03
Fifth and sixth gear shift fork pad thickness wear limit
0.258
6.55
See Figure 1. The 6-speed transmission consists of two parallel shafts supporting six gears each. The longer, or mainshaft
(7), also supports the clutch and serves as the input shaft. The shorter shaft is called the countershaft (8).
Each gear on the mainshaft is in constant mesh with a corresponding gear on the countershaft. Each of these six pairs of
gears makes up a different speed in the transmission.
The transmission gears are divided into two types, gears that rotate with the shaft, and gears that spin freely on the shaft.
A gear that rotates with the shaft always meshes with a freewheeling gear. Also, three dog rings are able to slide sideways
on the shaft. These dog rings are used to change transmission speeds. The dogs on the sides of dog rings engage dogs
on adjacent freewheeling gears, transmitting power through the transmission.
Gear shifting is accomplished by three forks which fit into grooves machined into the dog rings that slide on the guide hubs.
The position of the shifter forks is controlled by a drum-shaped shifter cam located in the transmission bearing housing.
Neutral
Power is introduced to the transmission through the clutch. In neutral, with the clutch engaged, the mainshaft first,
second, third and fourth gears are rotating. No power is transferred to the countershaft since countershaft first,
second, third and fourth gears are freewheeling gears.
First Gear
When the transmission is shifted into first gear, the dog ring between countershaft first and second, which rotates with
the countershaft, engages countershaft first, which has been spinning freely on the countershaft driven by mainshaft
first.
Now countershaft first is no longer freewheeling, but locked to the countershaft causing the countershaft and
countershaft sixth to turn. Countershaft sixth transmits the power to the main drive gear and the sprocket as shown
(1).
Second Gear
Second gear is engaged when the dog ring between countershaft first and second is shifted out of countershaft first
and engages countershaft second. This locks countershaft second to the countershaft to complete the power flow as
shown (2).
Third Gear
Two shifter forks are used to make the shift from second to third. One fork moves the dog ring between countershaft
first and second to its neutral position. At the same time another fork engages the dog ring between countershaft third
and fourth with countershaft third. This locks countershaft third to the countershaft to complete the power flow as
shown (3).
Fourth Gear
Fourth gear is engaged when the dog ring between countershaft third and fourth is shifted out of countershaft third and
engages countershaft fourth. This locks countershaft fourth to the countershaft to complete the power flow as shown
(4).
Fifth Gear
Two shifter forks are used to make the shift from fourth to fifth. One fork moves the dog ring between countershaft third
and fourth to its neutral position. At the same time another fork engages the dog ring between mainshaft fifth and sixth
with mainshaft fifth. This locks mainshaft fifth to the mainshaft to complete the power flow as shown (5).
Sixth Gear
The shift from fifth to sixth gear occurs when the dog ring between mainshaft fifth and sixth is shifted out of mainshaft
fifth. It is shifted directly into the main drive gear (sixth gear). The main drive gear is locked to the mainshaft. this
results in a direct one-to-one drive ratio from the clutch to the sprocket as shown (6).
1
First gear
2
Second gear
3
Third gear
4
Fourth gear
5
Fifth gear
6
Sixth gear
7
Mainshaft
8
Countershaft
Figure 1. Transmission Power Flow
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable
before proceeding. (00048a)
1. Disconnect negative battery cable. See Main Fuse.
2. Remove saddlebags if equipped. See Remove and Install: Standard
3. Remove mufflers and exhaust bracket. See Prepare
4. Remove rear wheel. See Prepare.
5. Remove rider footboard and bracket, if needed. See Prepare.
6. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
7. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
8. Remove primary chaincase cover. See Prepare.
9. Remove starter. See Prepare.
10. Remove primary chain, clutch and compensating sprocket. See Prepare.
11. Remove primary chaincase housing. See Prepare.
1. See Drive Belt. Loosen pivot shaft.
a. Remove nut (1).
NOTE
Hold pivot shaft while loosening nut.
b. See Rear Fork Assembly. Loosen pivot shaft pinch
bolt.
c. See Drive Belt. Slide pivot shaft out enough to
remove round spacer (2).
2. Remove slot spacer.
a.
Remove screws (5).
b.
Remove slot spacer (4).
3. Remove belt (3).
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