Harley Davidson 2018 softail models. Service manual — page 19
1. See Figure 1. Remove five sealing screws (5).
2. Remove primary chaincase housing (6).
3. Discard the crankcase gasket (7) and sealing screws.
1
Seal
2
Retaining ring
3
Bearing
4
Hollow dowel (4)
5
Sealing screw (5)
6
Primary chaincase housing
7
Crankcase gasket
Figure 1. Primary Chaincase Housing
1. Inspect primary chaincase for cracks or damaged gasket surface.
2. Check the mainshaft bearing. Replace if bearing does not rotate freely. See Mainshaft Bearing and Seal.
3. Replace the oil seal. See Mainshaft Bearing and Seal.
4. Inspect shifter shaft bushing. Replace if necessary. See Shifter Shaft Bushing.
NOTE
Cover mainshaft clutch hub splines with tape to prevent the splines from damaging the primary housing inner oil seal.
1. See Figure 2. Install gasket on surface (2). Verify dowels
in gasket engage dowel holes (3).
2. Spread a film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket.
3. Install primary chaincase housing.
a. See Figure 3. Install new sealing screws.
b. See Figure 4. Tighten in sequence shown. Torque:
35.3-38 N·m (26-28 ft-lbs) Primary chaincase
sealing screws
1
Dowel
2
Crankcase gasket
Figure 1. Crankcase Gasket
1
Crankcase
2
Gasket surface
3
Dowel holes
Figure 2. Crankcase
Figure 3. Primary Chaincase Sealing Screw
Figure 4. Sealing Screw Tightening Sequence
Remove
1.
Remove seal with a seal remover or rolling head pry bar
for best results.
WARNING
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)
2.
See Figure 1. Remove retaining ring (1).
NOTE
Support the bearing support area on the
transmission side of the primary chaincase while
pressing out bearing.
3.
Place inner primary chaincase in a press with clutch
side up.
4.
Press out bearing from clutch side.
Install
1. Verify that the bearing bore is clean and smooth.
NOTE
Support the bearing support area on the clutch side of the primary chaincase while pressing bearing.
2. Place primary chaincase in a press with the transmission side up.
3. Install new bearing with letter side up.
a. Apply a thin film of oil to outer diameter of bearing.
b. Press outer race until it makes solid contact with the bearing support area.
4. See Figure 1. Install retaining ring.
a. Retaining ring (1) must not block oil passage (2).
b. Verify that the ring is fully seated in the groove.
5. Install mainshaft oil seal.
a. Lubricate the OD of the new seal with SCREAMIN' EAGLE ASSEMBLY LUBE.
b. Place over bore with the lip garter spring side (stamped "OIL SIDE") facing toward the bearing.
c. Press against the outer rim of oil seal the seal until seal is flush with machined surface of inner primary
housing.
6. Lubricate the bearing and seal lip with multi-purpose grease or SCREAMIN' EAGLE ASSEMBLY LUBE.
1
Retaining ring
2
Oil passage
Figure 1. Retaining Ring Orientation
Special Tools
Description
Part Number
Qty.
BEARING RACE REMOVER AND
HD-34902-C
1
INSTALLER KIT
Remove
NOTE
Use only BEARING RACE REMOVER AND INSTALLER KIT (Part Number:HD-34902-C).
1. See Figure 1. Remove bearing inner race using BEARING RACE REMOVER AND INSTALLER KIT (Part
Number:HD-34902-C).
1
Bearing inner race
2
End cap
3
Puller
4
Forcing screw
Figure 1. Pulling Mainshaft Inner Bearing Race
Install
1. See Figure 2. Install bearing inner race (1) onto mainshaft using BEARING RACE REMOVER AND
INSTALLER KIT (Part Number:HD-34902-C).
2. Lubricate race with SCREAMIN' EAGLE ASSEMBLY LUBE.
1
Bearing inner race
2
Extension shaft
3
Wrench flat
4
Installer sleeve
5
Washer (2)
6
Nut
Figure 2. Installing Bearing Race
1. See Figure 1. Press out old bushing (1) from front to back.
2. Inspect the bushing bore to verify that it is clean and smooth.
3. Press new bushing from back of chaincase until it is flush to 0.51 mm (0.020 in) below edge of bore.
1
Shifter shaft bushing
2
Primary chaincase
Figure 1. Shifter Shaft Bushing
1. Install the primary chain, clutch, compensating sprocket and chain tensioner. See Prepare.
2. Install starter. See Prepare.
3. Install primary chaincase cover and new gasket. See Prepare.
4. Fill primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Mid-mount controls: Install foot shift lever. See Shifter Rod.
6. Install rider left footboard and bracket, if removed. See Prepare.
7. Connect negative battery cable. See Main Fuse.
1. Drain engine oil. See Check Engine Oil Level.
1. See Engine Oil Fill Spout. Remove screws (4).
2. Remove fill spout (3).
3. Discard O-ring (1).
1. See Figure 1. Install new O-ring (1).
2. Install fill spout.
a. Install fill spout (3).
b. Install screws (4). Tighten.
Torque: 11.3-13.6 N·m (100-120 in-lbs) Engine oil
fill spout screw.
1
O-ring
2
Dipstick
3
Fill spout
4
Screw (2)
Figure 1. Engine Oil Fill Spout
1. Fill engine oil. See Check Engine Oil Level.
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 rider footboard and bracket, if needed. See Prepare.
3. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
4. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
5. Remove primary chaincase cover. See Prepare.
6. Remove starter. See Prepare.
7. Remove primary chain, clutch and compensating sprocket. See Prepare.
8. Remove primary chaincase housing. See Prepare.
9. Loosen drive belt. See Inspect.
Special Tools
Description
Part Number
Qty.
FINAL DRIVE SPROCKET
HD-46282A
1
LOCKING TOOL
MAINSHAFT LOCKNUT WRENCH
HD-47910
1
PILOT
HD-94660-2
1
NOTE
Loosen sprocket nut only while transmission is installed in frame. Otherwise damage to transmission or
transmission stand results.
Sprocket nut has a right-hand thread.
1. See Figure 1. Remove sprocket nut.
a. Remove two screws (1) and lockplate (2).
b. See Figure 2. Install FINAL DRIVE SPROCKET LOCKING TOOL (Part Number:HD-46282A) (2) with arm
of tool against bottom of rear fork pivot (1).
c. Install PILOT (Part Number:HD-94660-2) on mainshaft.
d. Remove the sprocket nut (3) using MAINSHAFT LOCKNUT WRENCH (Part Number:HD-47910) (1).
2. Remove sprocket, allowing belt to slip from sprocket as sprocket is removed.
1
Screw (2)
2
Lockplate
3
Sprocket nut
4
Sprocket
5
Main drive gear
Figure 1. Transmission Sprocket
1
Rear fork pivot
2
Final drive sprocket locking tool
3
Sprocket nut
Figure 2. Sprocket Nut Removal
1. Using a non-volatile cleaning solvent, clean sprocket of all grease and dirt.
2. Inspect belt and sprocket. See Inspect.
3. Inspect main drive gear and mainshaft seals. Replace if damaged.
Special Tools
Description
Part Number
Qty.
FINAL DRIVE SPROCKET
HD-46282A
1
LOCKING TOOL
MAINSHAFT LOCKNUT WRENCH
HD-47910
1
PILOT
HD-94660-2
1
TORQUE ANGLE GAUGE
TA360
1
NOTE
Tighten sprocket nut only while transmission is installed in frame. Otherwise damage to transmission or
transmission stand results.
Never get oil on the threads of the sprocket nut.
The transmission sprocket nut has right-hand threads.
1.
Place transmission sprocket in position. Install the belt as
the sprocket is installed.
2.
Install sprocket nut.
a. See Transmission Sprocket. Apply a film of clean
engine oil to the mating surfaces of the sprocket nut
(3) and the sprocket (4).
b. If reusing the sprocket nut, apply LOCTITE 271 HIGH
STRENGTH THREADLOCKER (red) to the threads of
the sprocket nut.
c. Install the sprocket nut finger-tight.
d. See Figure 1. Install FINAL DRIVE SPROCKET
LOCKING TOOL (Part Number:HD-46282A) (2)
resting against the rear fork pivot (3).
e. Install PILOT (Part Number:HD-94660-2) on
mainshaft.
f. Using MAINSHAFT LOCKNUT WRENCH (Part
Number:HD-47910), tighten sprocket nut to
135.6 N·m (100 ft-lbs) initial torque.
3.
Loosen sprocket nut one full turn.
4.
Tighten to 47.5 N·m (35 ft-lbs).
NOTE
See Figure 2. Scribe lines (3) or use TORQUE
ANGLE GAUGE (Part Number:TA360) for final
torque.
5.
Turn sprocket nut an additional 35-40° (35-40°).
NOTE
The lockplate can be installed either side out.
Never LOOSEN nut to align screw holes.
If necessary, tighten the nut slightly to align
lockplate.
Do not exceed a final torque of 45 degrees.
6. Install lockplate.
a. Align lockplate holes with tapped holes in sprocket.
b. See Transmission Sprocket. Install two new screws
(1).
c. Tighten to 10.2-13.6 N·m (90-120 in-lbs).
1
Sprocket nut
2
Final drive sprocket locking tool
3
Rear fork pivot
Figure 1. Sprocket Nut Installation
1
Transmission sprocket nut
2
Transmission sprocket
3
Scribed lines
Figure 2. Transmission Sprocket Nut Final Tightening
1. Install primary chaincase housing. See Prepare.
2. Install the primary chain, clutch, compensating sprocket and chain tensioner. See Prepare.
3. Install starter. See Prepare.
4. Install primary chaincase cover and new gasket. See Prepare.
5. Fill primary chaincase oil. See Change Primary Chaincase Lubricant.
6. Mid-mount controls: Install foot shift lever. See Shifter Rod.
7. Install rider left footboard and bracket, if removed. See Prepare.
8. Adjust drive belt deflection. See Inspect.
9. Verify rear fork pivot shaft torque. See Prepare.
10. Connect negative battery cable. See Main Fuse.
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. Drain transmission oil. See Check Transmission Lubricant.
3. Drain engine oil. See Check Engine Oil Level.
4. Remove exhaust system. See Prepare.
5. Remove engine oil fill spout. See Prepare.
6. Remove clutch release cover. See Prepare.
7. Remove rider footboard and bracket, if needed. See Prepare.
8. Mid-mount controls: Remove foot shift lever. See Shifter Rod.
9. Drain primary chaincase oil. See Change Primary Chaincase Lubricant.
10. Remove primary chaincase cover. See Prepare.
11. Remove starter. See Prepare.
12. Remove primary chain, clutch and compensating sprocket. See Prepare.
13. Remove primary chaincase housing. See Prepare.
14. Loosen drive belt. See Inspect.
15. Remove transmission mainshaft bearing inner race. See Mainshaft Bearing Inner Race.
NOTE
Do not remove the transmission case unless the case requires replacement. See Prepare.
1. See Figure 1. Remove oil slinger assembly and pushrod from main shaft.
2. Remove transmission top cover.
3. See Figure 2. Set a rag over the transmission case.
4. Set shifter cam pawl on rag.
5. Cover mainshaft clutch hub splines with tape to prevent damaging the main drive gear bearings and oil seal.
NOTE
See Figure 3. Always pry bearing housing loose. Never tap on shafts to remove transmission assembly. The bearing
housing bearings will be damaged.
6. See Figure 4. Remove the transmission and bearing housing assembly:
a. Remove the transmission bearing housing screws (1).
b. See Figure 3. Pry the bearing housing loose.
c. Remove bearing housing and transmission components from transmission case as an assembly.
1
Retaining ring
2
Thrust washer (2)
3
Throw out bearing
4
Oil slinger
5
Push rod
6
Push rod end, left side
Figure 1. Push Rod Assembly
1
Shifter pawl
2
Rag
Figure 2. Transmission Shifter Pawl
Figure 3. Bearing Housing Pry Point
1
Screw (8)
Figure 4. Bearing Housing Screws
1. Cover mainshaft clutch hub splines with tape to prevent
damaging the main drive gear bearings and oil seal.
2. Install a new gasket on the ring dowels.
3. Apply clean transmission lubricant to the main drive gear
bearings.
NOTE
Verify that transmission filler plug/dipstick is removed.
4. Install the transmission assembly in the transmission
case.
5. See Bearing Housing Screws. Install transmission
bearing housing.
a. Install screws (1).
b. See Figure 1. Tighten in sequence to 29.8-33.9 N·m
(22-25 ft-lbs).
Figure 1. Transmission Bearing Housing Tightening Sequence
6. Install top cover.
a. Set shifter cam pawl on shift cam.
b. Inspect transmission top cover gasket. Replace as
necessary.
c. Install transmission top cover and screws. Tighten.
Torque: 14.9-17.6 N·m (132-156 in-lbs)
Transmission top cover
7. Install vent hose to top cover fitting, if removed.
8. See Push Rod Assembly. Install pushrod assembly (2-5)
in mainshaft hole.
a. Install new retaining ring (1) if removed.
Remove Shift Cam and Shifter Forks
1. See Figure 1. Remove shift fork shafts:
a. Set bearing housing on bench with shafts pointing up.
NOTE
Shafts have slight interference fit.
b. Remove shift fork shafts using spiral-flute screw extractor (14) or vise grips.
c. Mark end of shaft to aid assembly.
2. Remove shift forks from dog rings.
3. See Figure 2. Remove lock plate (2). Discard screws (3).
4. Hold detent arm back and remove shift cam (4).
5. See Figure 3. If needed, remove detent assembly.
a. Remove detent screw (1), detent arm (2), sleeve (3) and detent spring (4).
b. Discard detent screw.
NOTE
Mark parts so they can be installed in same direction as removed.
6. See Figure 4. Remove mainshaft and countershaft locknuts.
a. Lock two gears in place using dog rings.
b. Temporarily put transmission assembly into transmission case.
c. Remove locknuts.
d. Remove transmission assembly from transmission case.
1
Mainshaft
2
Countershaft
3
Mainshaft first gear
4
Mainshaft second gear
5
Mainshaft third gear
6
Mainshaft fourth gear
7
Mainshaft fifth gear
8
Countershaft first gear
9
Countershaft second gear
10
Countershaft third gear
11
Countershaft fourth gear
12
Countershaft fifth gear
13
Countershaft sixth gear
14
Screw extractor
Figure 1. Gear Set
1
Bearing housing
2
Lock plate
3
Lock plate screw (2)
4
Shift cam
Figure 2. Shift Drum
1
Detent screw
2
Detent arm
3
Sleeve
4
Detent spring
Figure 3. Detent Assembly
1
Retaining ring (2)
2
Bearing (2)
3
Mainshaft locknut
4
Countershaft locknut
Figure 4. Bearing Housing Locknuts
Remove Mainshaft
NOTE
The mainshaft fourth gear, third gear, second gear and first gear are integral parts of the shaft. Damage to
any gear requires mainshaft replacement.
Always replace bearing housing bearings.
1. See Figure 5. Using 714 (OTC HORSESHOE LOCK RING PLIERS,), remove retaining ring.
2. Remove dog ring (3), guiding hub (2), mainshaft fifth gear (4) and bearing.
NOTE
Do not press directly on the end of the mainshaft. Use a spacer between the end of the mainshaft and the press
ram.
3. Press mainshaft out of bearing housing bearing.
4. Replace bearing housing bearing. See procedure later in this section.
1
Retaining ring pliers
2
Guiding hub
3
Dog ring
4
Mainshaft fifth gear
Figure 5. Mainshaft Fifth Gear
Remove Countershaft
NOTE
Do not press directly on the end of the countershaft. Place a spacer between the end of the countershaft and the
press ram.
1. If mainshaft is not removed, hold countershaft third and fourth gear shift dog up while removing countershaft.
2. Press countershaft out of bearing housing bearing.
3. See Figure 6. Remove washer (1), countershaft first gear (2) and bearing.
4. Remove countershaft second, third and forth gears.
a. See Figure 7. Remove dog ring (5).
b. Remove lock ring (1).
c. Remove securing segments (2).
d. Remove guiding hub (3), countershaft second gear (4) and bearing.
e. See Figure 8 and Figure 9. Repeat steps with third and fourth gears.
NOTE
The countershaft fifth gear and sixth gear are integral parts of the shaft. Damage to either gear requires
countershaft replacement.
5. Replace bearing housing bearing. See procedure later in this section.
1
Washer
2
Countershaft scissor first gear
Figure 6. Countershaft First Gear
1
Lock ring
2
Securing segment (2)
3
Guiding hub
4
Countershaft second gear
5
Dog ring
Figure 7. Countershaft Second Gear
1
Lock ring
2
Securing segment (2)
3
Internal spline washer
4
Countershaft third gear
Figure 8. Countershaft Third Gear
1
Lock ring
2
Securing segment (2) (not visible)
3
Guiding hub
4
Countershaft fourth gear
5
Dog ring
Figure 9. Countershaft Fourth Gear
Remove Bearing Housing Bearings
NOTE
Always replace bearing housing bearing if the shaft is pressed out.
1. See Figure 10. Remove the retaining rings (2). Discard retaining rings.
2. Press the bearings out of the bearing housing.
1
Retaining ring (2)
2
Bearing (2)
3
Bearing housing
Figure 10. Bearing Housing Bearings
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)
1. Clean parts in a non-volatile cleaning solution. Dry parts with low-pressure, compressed air.
2. Replace gears that are worn or damaged.
3. Replace the dog rings if dogs and/or pockets are rounded, battered or chipped.
4. Replace guiding hubs if splines are rounded, battered or chipped.
5. Replace shift fork shafts if bent or damaged.
6. Replace a shift fork if it is excessively worn or shows signs of overheating.
7. See Figure 1. Using a small square, verify that the shift forks are square. Replace shift fork if not square.
8. Replace shift drum assembly if drum or bearing are damaged.
9. Clean shift cam lock plate mounting holes in transmission bearing housing.
Figure 1. Checking Fork
Install Bearing Housing Bearings
NOTE
Always replace bearing housing bearing if the shaft was removed.
Always support the bearing housing with a plate when pressing bearings.
Press on the bearing outer race.
1.
Install bearings.
a. Support the bearing housing at the bearing bores
with a flat plate.
b. Position new bearing over bore with number side
up.
c. Press the bearing until seated in the bore.
WARNING
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)
2.
See Bearing Housing Bearings. Install new beveled
retaining ring (1) with the flat side against the bearing.
Install Countershaft
1. Install fourth, third and second gears on countershaft.
a. See Countershaft Fourth Gear. Install countershaft fourth gear (4).
b. Lubricate needle bearings and races with SCREAMIN' EAGLE ASSEMBLY LUBE.
c. Install new needle bearing.
d. Install guiding hub (3).
e. Install dog ring (5).
f. Install securing segments (2) with the rounded edge facing up. Verify that segments fully engage
grooves in countershaft.
g. Install lock ring (1) with waved, stepped face toward the securing segments.
h. See Countershaft Third Gear. Install countershaft third gear (4).
NOTE
Install the second gear guiding hub with the deeper counterbore facing countershaft second gear.
i. See Countershaft Second Gear. Install countershaft second gear (4).
2. See Figure 1. Preload scissor first gear.
a. While holding thick gear, rotate thin gear until holes align.
b. Install HD-52235 (SCISSOR FIRST GEAR TOOL).
3. See Countershaft First Gear. Install new needle bearing, countershaft first gear (2) and washer (1).
NOTE
If installing countershaft with mainshaft installed, raise and hold countershaft third and fourth gear shift dog
up while pressing bearing housing bearing on to countershaft.
Failure to press on bearing inner race damages the bearing.
4. See Figure 3. If mainshaft is not removed, raise and hold countershaft third and fourth gear shift dog while
installing countershaft.
5. See Figure 2. Install countershaft to bearing housing.
a. Support countershaft sixth gear in press.
b. Using a suitable sleeve, press on bearing inner race until bearing contacts countershaft first gear
washer.
Figure 1. Preload Scissor First Gear
Figure 2. Installing Countershaft
Install Mainshaft
NOTE
Failure to press on bearing inner race damages the bearing.
1.
Support mainshaft fourth gear in press.
2.
See Figure 3. Raise and hold dog ring engaged with
countershaft third gear during the press procedure.
3.
Using a suitable sleeve, press on bearing inner race until
bearing contacts mainshaft first gear.
4.
See Mainshaft Fifth Gear. With bearing housing on end
(shafts pointing up), install new bearing and mainshaft
fifth gear (4).
5.
With guiding hub counterbore facing mainshaft fifth gear,
install guiding hub (2) and dog ring (3).
6.
Install new retaining ring using 714 (OTC HORSESHOE
LOCK RING PLIERS,) (1).
7.
Remove holding tool from scissor first gear.
8.
Install new mainshaft and countershaft locknuts.
a. Using dog rings, lock two gears in place.
b. Temporarily install transmission assembly in
transmission case.
c. Install locknuts. Tighten to 115.3-128.8 N·m (85-95
ft-lbs).
d. Remove transmission assembly from transmission
case.
Figure 3. Raise and Hold Dog Ring
Install Shifter Cam/Shifter Forks
1. Set bearing housing on bench with shafts pointing up.
2. Install detent arm assembly, if removed.
a. See Figure 4. Clean detent screw mounting hole in
transmission bearing housing.
b. Assemble new detent screw (1), detent arm (2),
sleeve (3) and detent spring (4).
c. Align spring and detent arm as shown.
d. Install detent assembly in bearing housing with
screw (1).
e. Tighten.
Torque: 13.6-17 N·m (120-150 in-lbs) Shift drum
detent screw
Torque: 13.6-17 N·m (120-150 in-lbs) Shift drum
detent screw
3.
See Figure 5. Hold detent arm back and install shift
cam assembly (4).
4.
Install lock plate (2) and new lock plate screws (3).
Tighten..
Torque: 6.4-7.1 N·m (57-63 in-lbs) Shift drum lock
plate screws
Torque: 6.4-7.1 N·m (57-63 in-lbs) Shift drum lock
plate screws
5.
Remove any burrs created on shift shafts (1, 3)
during removal.
NOTE
See Figure 6. The shifter forks are unique and
identified as shown.
6.
See Figure 7. Install long shift shaft (1):
a. Insert shifter fork (2) into the dog ring between
mainshaft fifth and sixth gear.
b. Slide shift shaft through shifter fork.
c. Install shaft in hole in bearing housing.
7.
Install short shift shaft (4):
a. Insert shifter fork (6) into the dog ring between
countershaft third and fourth gear.
b. Insert shifter fork (9) into the dog ring between
countershaft first and second gear.
c. Slide shift shaft through shifter forks.
d. Install shaft in bearing housing.
1
Detent screw
2
Detent arm
3
Sleeve
4
Detent spring
Figure 4. Detent Assembly
1
Bearing housing
2
Lock plate
3
Lock plate screw (2)
4
Shift cam
Figure 5. Shift Drum
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