Harley Davidson military motorcycle model 42WLA-Solo. Operation and maintenance Manual (August, 1942) — page 3

Removing Clutch Hub

Remove clutch hub nut (Item 74). On 1940 models use manufacturer's wrench number 12745-26 with adapter number 12745-26A; on 1941 and later models use wrench number 12745-41.

1940 model: Clutch hub can be removed from taper by giving it a light but sharp rap with a hammer and soft punch, striking close to center but being careful not to strike bearing.

1941 and later models: Clutch hub is a press fit on splined end of clutch gear. Puller number 12022-41 is needed to remove it.

Inspection of Parts

Inspect all parts and determine which must be renewed. Check all gears for extent of tooth wear; also inspect all bushings and bearing races.

Give especially close attention to possibly battered or rounded condition of engaging dogs on shifter clutches and clutch gear and engaging slots in other gears. This condition results from shifting abuses or possibly from poorly adjusted clutch that does not release fully.

Damaged engaging dogs and slots try to creep out of engagement under steady driving load. This creeping action develops tremendous side pressure that finally results in serious damage to shifting mechanism and all thrust points along the mainshaft assembly. Therefore, in doing a thorough and dependable transmission overhaul, it is of prime importance that all gears and shifter clutches with badly rounded engaging dogs and slots be replaced with new.

Installing Clutch Gear

A. Assuming that oil seal (Item 71) and bearing retaining washer (Item 70) are already assembled in case, install roller bearing end washer (Item 17) in roller race next. Assemble rollers (Item 16) in roller race after applying sufficient grease to race to hold rollers in place.

B. Insert oil seal tool (manufacturer's tool number 12747-41) through oil seal from the outside so that it will be in place to meet clutch gear when it is inserted through bearing from the inside. It is necessary that this oil seal tool be used to facilitate assembly and avoid damaging oil seal. Assemble thrust bearing race (Item 14) and retainer and balls (Item 15) on clutch gear. Now insert clutch gear through bearing from inside of case. Be sure end of

gear is engaged with oil seal tool before pushing it through seal.

Adjusting Mainshaft Endplay

A. Install mainshaft in case with mainshaft spacer (Item 24), thrust washer (Item 35) and spacing collar (Item 36) in place.

B. Install roller bearings (Item 37) in side cover bearing race, holding them in place by means of light coat of grease.

C. Install side cover and gasket on transmission case. In checking endplay, it is important to tighten cover screws and stud nuts just as tight as in final assembly; otherwise endplay in final assembly will not be the same as this check shows. Check endplay as indicated in Illustration 53; it should be .003" to .005". Increase or decrease endplay as necessary by fitting mainshaft spacer (Item 24) of required thickness.

D. After correct mainshaft endplay has been established, remove mainshaft from case and set aside spacer washer selected, to be sure it goes into final assembly.

Adjusting Endplay of Low and Second Gears Between Retaining Bracket and Transmission Side Cover

A. Assemble only the following parts on mainshaft: From left (clutch) end—low gear end thrust washer (Item 32), low gear (Item 31), endplay adjusting washer (Item 30), second gear (Item 29), mainshaft spacer (Item 24); from right (sprocket) end— thrust washer (Item 35) and spacing collar (Item 36).

B. Install roller bearings in side cover and install gasket and cover on case. Tighten cover just as tight as in final assembly.

C. Check endplay of low and second gears between sidecover (Item 40) and second gear retaining bracket (Item 26), as indicated in Illustration 53. Measure by means of thickness gauge inserted between second gear retaining bracket and second gear. Endplay should be .005" to .007". Adjust as necessary by fitting endplay adjusting washer (Item 30) of required thickness.

After correct endplay adjustment has been attained, remove mainshaft assembly from transmission. Be sure selected endplay washer remains with the assembly.

Assembling Transmission

After mainshaft spacer (Item 24) and endplay adjusting washer (Item 30) in their required thicknesses have been selected, complete assembly of transmission can proceed, reversing order of disassembly.

If new shifter clutches (Items 25 and 34) are required, see that they fit free on mainshaft and slide on shaft splines without binding. Shifting will be difficult unless these parts work freely.

When assembling shifter cam, two things must be watched very closely: First, shifter finger rollers must be in place on shifter fingers; second, shifter cam gear and shifter lever gear must be correctly timed. Small gear has one tooth chamfered at end. This tooth must engage with space marked "3" between teeth of large gear. See Illustration 54.