Harley Davidson 2008 Touring Models. Service Manual - page 39

10. Install end cover bracket onto threaded end of thru bolts,

if equipped. For proper orientation, be sure that the longest
end of the bracket (before the bend) is on the field wire
side. Install two Keps nuts and alternately tighten until
snug.

11. Install allen head screw to fasten chrome end cover to end

cover bracket, if equipped. Tighten screw to 90-110 in-
lbs (10.2-12.4 Nm).

sm03714

Figure 5-9. Install Paper Clips to Hold Brush Springs

DRIVE ASSEMBLY

Disassembly

Remove field coil. See

5.2 STARTER, Field Coil Assembly

Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.

Using a 9 mm socket, remove two hex screws with Phillips
recess to release drive housing from solenoid housing.

Use a rubber mallet to separate drive and solenoid hous-
ings, if necessary.

Remove idler gear from bearing cage in drive housing.
Remove bearing cage with five steel cylinders from shaft
in drive housing.

Push on end of drive shaft to remove starter clutch
assembly from drive housing.

Compressing internal springs, remove snap ring from
groove at end of drive shaft.

Remove cup, pinion gear, short spring and spring seat
from splined end of drive shaft.

Push on splined end of drive shaft to remove from starter
clutch bore.

10. Remove long spring from drive shaft. Remove steel ball

from drive shaft bore.

11. Remove return spring from solenoid plunger shaft.

Inspection

Inspect two o-rings in drive housing bore for cuts, tears or
signs of deterioration.

Replace springs if kinked, elongated or distorted.

Inspect pinion gear and drive shaft gear. Replace if pitted,
scored, rounded, cracked, chipped or worn.

Inspect roller bearings. Bearings must rotate freely without
drag or sticking. Replace the bearings if pitted or grooved.

Inspect the steel ball for wear, pitting, surface breakdown
or other damage.

Replace snap ring if bent or distorted.

Assembly

Install long spring onto drive shaft. Install steel ball in drive
shaft bore. Insert splined end of drive shaft into starter
clutch bore (gear side).

Insert a deepwell socket into starter clutch bore and stand
assembly upright on work bench with the socket side
down.

Push down on starter clutch, so that installed socket
pushes against the drive shaft gear to compress the spring.
Holding assembly with spring compressed, install spring
seat, short spring, pinion gear and cup on splined end of
drive shaft. Be sure that the collar on the pinion gear and
the concave side of the cup both face the splined end of
the drive shaft.

While pushing down to simultaneously compress both the
long and short springs installed, install snap ring in groove
at splined end of drive shaft. Verify that snap ring is fully
seated in the groove and that it resides in concave portion
of cup when spring tension is released.

Remove deepwell socket from starter clutch bore.

Install bearing cage with five steel cylinders onto shaft in
drive housing. Be sure that all five steel cylinders are
installed in grooves of bearing cage. Install idler gear over
bearing cage. Lubricate parts with high temperature
grease, such as LUBRIPLATE 110, during assembly.

Install starter clutch assembly in drive housing seating the
larger bearing in the counterbore. Lubricate bearings with
LUBRIPLATE 110 before installation.

Apply a light film of Lubriplate 110 to solenoid plunger
shaft. Install return spring on solenoid plunger shaft.

Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.

10. Lubricate armature bearing with LUBRIPLATE 110.

Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.

11. Install field coil. See

5.2 STARTER, Field Coil Assembly

2008 Touring Service: Starter 5-7

5.3

STARTER SOLENOID

SOLENOID ASSEMBLY

Disassembly

Remove field coil. See

5.2 STARTER, Field Coil Assembly

Pull field coil with end cap from solenoid housing. Hold
end cap to field coil to avoid pulling armature out of brush
holder. If armature is pulled from brush holder, further
disassembly is required.

Using a 9 mm socket, remove two hex screws with Phillips
recess to release solenoid housing from drive housing.

Use a rubber mallet to separate solenoid and drive hous-
ings, if necessary.

Remove return spring from solenoid plunger shaft.

Assembly

Install return spring on solenoid plunger shaft.

Mate the solenoid and drive housings and install two hex
screws using a 9 mm socket. Alternately tighten hex
screws until snug.

Lubricate armature bearing with LUBRIPLATE 110.
Seating armature bearing in counterbore, mate field coil
and solenoid housings. For proper assembly, a nub on
the field coil housing flange must engage the slot on
solenoid housing flange closest to the short (field wire)
post on the solenoid housing.

Install field coil. See

5.2 STARTER, Field Coil Assembly

SOLENOID PLUNGER

Disassembly

Remove three hex screws to release solenoid cover.

Remove rubber gasket from solenoid cover flange.

Remove plunger and return spring.

Assembly

Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.

Install new rubber gasket on solenoid cover flange.

Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.

SOLENOID CONTACTS

Disassembly

Remove three hex screws to release solenoid cover.

Remove rubber gasket from solenoid cover flange.

Remove plunger and return spring.

Obtain Solenoid Contact Repair Kit.

Disassemble short post (field coil):

See

Figure 5-10

. Remove hex nut from post, if still

installed. Remove jam nut, wave washer, round
bushing and o-ring from post.

On inside of solenoid housing, remove post bolt, hold-
in terminal, contact plate and square bushing.

Disassemble long post (battery):

Remove hex nut from post, if still installed. Remove
jam nut, wave washer, round bushing and o-ring from
post.

On inside of solenoid housing, remove post bolt,
contact plate, square bushing and paper insulator
washer.

5-8 2008 Touring Service: Starter

sm03715

10.

Wave washer

Solenoid

11.

Hex screw

O-ring

12.

Round bushing

Solenoid cover

13.

Rubber gasket

Square bushing

14.

Contact plate

Plunger

15.

Return spring

Post bolt

16.

Paper insulator washer

Rubber boot

17.

Hex nut

Hold-in terminal

Jam nut

Figure 5-10. Solenoid Assembly

Assembly

Assemble short post (field coil):

From inside solenoid housing, insert sleeve on square
bushing into hole in solenoid housing.

With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.

Slide short post bolt through holes in hold-in terminal,
contact plate, square bushing and solenoid housing.

At outside of solenoid housing, install round bushing,
O-ring and wave washer onto end of post. Install jam
nut, but do not tighten.

Assemble long post (battery):

On inside of solenoid housing, align hole in paper
insulator washer with hole in solenoid housing. Insert
sleeve on square bushing into holes.

With the foot inboard against solenoid winding, align
hole in contact plate with hole in square bushing.

Slide long post bolt through holes in contact plate,
square bushing, paper insulator washer and solenoid
housing.

At outside of solenoid housing, install round bushing,
o-ring and wave washer onto end of post. Verify that
index pin on round bushing engages blind hole in
solenoid housing. Install jam nut, but do not tighten.

Apply a light film of LUBRIPLATE 110 to plunger shaft and
install return spring. Install plunger in solenoid.

2008 Touring Service: Starter 5-9

While depressing plunger, alternately tighten jam nuts to
65-80 in-lbs (7.3-9.0 Nm). Verify that contact plates have
not rotated out of alignment with plunger.

Install new rubber gasket on solenoid cover flange.

Install three hex screws to secure solenoid cover. Altern-
ately tighten hex screws until snug.

5-10 2008 Touring Service: Starter

SUBJECT

............................................................................................................................

PAGE NO.

DRIVE

6.1

SPECIFICATIONS: DRIVE

SPECIFICATIONS

Table 6-1. Sprocket Specifications

NO. OF TEETH

SPROCKETS

DOM/HDI

Compensating

Clutch

Transmission

Rear Wheel

Table 6-2. Clutch Specifications

DESCRIPTION

CLUTCH

Wet-multiple disc

Type

1/16-1/8 in.

(1.6-3.2 mm)

Clutch lever freeplay
(after internal adjustment)

Table 6-3. Gear Specifications

OVERALL GEAR RATIO

GEAR

DOM/HDI

9.312

First (low)

6.421

Second

4.774

Third

3.926

Fourth

3.279

Fifth

2.790

Sixth (high)

NOTE

Overall gear ratios indicate number of engine revolutions
required to drive rear wheel one revolution.

2008 Touring Service: Drive 6-1

6.2

PRIMARY CHAINCASE COVER

GENERAL

The primary chaincase is a sealed housing containing the
primary chain, chain tensioner, clutch, engine compensating
sprocket and alternator.

For information on primary chain lubrication, see

1.9 PRIMARY

CHAIN

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect negative battery cable.

Drain the primary chaincase lubricant. See

1.9 PRIMARY

CHAIN, Chaincase Lubricant: Touring Models

Remove fastener to remove passenger footboard from
rear swingarm bracket.

Remove fastener to release front footboard forward bracket
from frame weldment. Remove two fasteners to free jiffy
stand and front footboard rear bracket from frame weld-
ment.

Remove heel and toe shift lever fasteners from shift lever
shaft and pull shift levers from shift lever shaft. Remove
rubber spacer. An alternate method is to remove socket
head fastener to release inner shift arm then pull shift lever
shaft and heel toe shift lever assembly from primary
chaincase bore.

See

Figure 6-1

. Remove short (1) and long (2) cover

fasteners and cover.

sm003716

Short cover fasteners

Long cover fasteners

Figure 6-1. Primary Chaincase Cover: Touring Models

INSTALLATION

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

See

Figure 6-2

. Install new cover gasket (1).

See

Figure 6-1

. Install short (1) and long (2) primary cover

fasteners in positions shown. Snug fasteners.

See

Figure 6-3

. Tighten primary cover fasteners (1-13) to

108-120 in-lbs (12.2-13.6 Nm) in the sequence shown.

Do not overfill the primary chaincase with lubricant.
Overfilling can cause rough clutch engagement, incom-
plete disengagement, clutch drag and/or difficulty in
finding neutral at engine idle. (00199b)

Place motorcycle in an upright position and fill primary
chaincase. See

1.9 PRIMARY CHAIN, Chaincase Lub-

ricant: Touring Models

If installing heel-toe shift levers onto shift lever shaft:

Install inboard shift lever (toe) onto splines of shift
lever shaft. When properly installed, fastener hole is
countersunk at the top.

Install outboard shift lever (heel) onto splines of shift
lever shaft. When properly installed, fastener hole is
countersunk at the bottom.

Install fasteners to fasten heel-toe shift levers to shift
lever shaft. Tighten shift lever fasteners to 18-22 ft-
lbs (24-30 Nm)

If just installing inner shift arm onto shift lever shaft:

Install rubber spacer onto shift lever shaft. Install shift
lever shaft into primary chaincase bore.

Install inner shift arm onto splines of shift lever shaft.

Install fastener to attach inner shift arm to shift lever
shaft. Tighten fastener to 90-110 in-lbs (10.2-12.4)

Connect negative battery cable.

6-2 2008 Touring Service: Drive

sm03717

Cover gasket

Primary chaincase cover

Mass dampener/screw (Japan only)

Figure 6-2. Primary Chaincase Cover Gasket: Touring

Models

sm003718

Figure 6-3. Primary Chaincase Cover Torque Sequence:

Touring Models

2008 Touring Service: Drive 6-3

6.3

DRIVE COMPONENTS

REMOVAL

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-47977

NOTES

To remove the primary chain, remove compensating sprocket,
clutch assembly and primary chain as an assembly:

Disconnect the battery, negative cable first.

Remove primary chaincase cover. See

6.2 PRIMARY

CHAINCASE COVER, Removal

See

Figure 6-4

. Secure chain tensioner with a cable tie

as shown. Make sure the tail of the cable tie hangs down
past the primary housing when secured. This will serve
as a reminder to remove the cable tie before installing the
primary cover during assembly.

See

Figure 6-5

. Remove chain tensioner fasteners (2)

then remove chain tensioner (1).

Using a colored marker, mark one of the links of the
primary chain. Maintaining the original direction of rotation
during assembly may prolong service life.

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)

See

Figure 6-6

. Loosen locknut (3).

Remove retaining ring (1) and release plate (2).

Do not apply heat to remove the clutch hub nut. Fuel vapor
and possible fuel mixture in crankcase oil is extremely
flammable and highly explosive, which could result in
death or serious injury. (00440b)

NOTES

•

See

Figure 6-7

. When removing the clutch hub mainshaft

nut the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) (2) must be placed between the teeth of the engine
and clutch sprockets.

•

Do not use PRIMARY DRIVE LOCKING TOOL (Part No.
HD-41214) to remove or install components. Damage to
components can occur if this tool is used. Use only
PRIMARY DRIVE LOCKING TOOL (Part No. HD-47977)
to remove and install components.

•

The mainshaft nut has left-hand threads, so turn clockwise
to remove.

Using a breaker bar, rotate clutch hub mainshaft nut in
direction shown to remove.

NOTE

See

Figure 6-8

. When removing the compensating sprocket

bolt, the PRIMARY DRIVE LOCKING TOOL (Part No. HD-

47977) must be placed between the teeth of the engine and
clutch sprockets.

Using a breaker bar, rotate compensating sprocket bolt in
direction shown to remove.

10. See

Figure 6-9

. Remove bolt (6) and washer (5).

NOTE

Using a colored marker or paint pen, mark one of the outboard
links of the primary chain. Maintaining the original direction of
rotation during assembly may prolong service life.

11. Remove clutch assembly, primary chain and compensating

sprocket assembly as a single assembly.

sm05036

Figure 6-4. Securing Chain Tensioner

sm02391

Chain tensioner

Chain tensioner fasteners

Figure 6-5. Chain Tensioner

6-4 2008 Touring Service: Drive

sm02393

Retaining ring

Release plate

Locknut

Figure 6-6. Clutch

sm02396

Engine sprocket

Primary drive locking tool

Clutch sprocket

Mainshaft nut

Figure 6-7. Removing Clutch Hub Mainshaft Nut

sm02400

Bolt

Primary drive locking tool

Figure 6-8. Removing Compensating Sprocket Bolt

sm02402

Rotor

Sliding cam

Compensating sprocket

Shaft extension

Washer

Bolt

Figure 6-9. Compensating Sprocket

INSTALLATION

TOOL NAME

PART NUMBER

PRIMARY DRIVE LOCKING TOOL

HD-47977

NOTE

The primary chain, compensating sprocket and clutch assembly
must be installed as an assembly.

See

Figure 6-10

. Apply a thin layer of primary chaincase

oil, to the inner diameter of the compensating sprocket

2008 Touring Service: Drive 6-5

(3). and the splines of shaft extension (4). Assemble shaft
extension, compensating sprocket and sliding cam (2).
Place primary chain over compensating sprocket
assembly.

Place drive components (primary chain, compensating
sprocket assembly, and clutch assembly) into position.
The clutch hub and shaft extension are splined, so a slight
rotation of the chain drive will aid installation.

If reusing bolt (6), remove threadlocking material from bolt
and engine sprocket shaft. Clean and prime threads of
bolt and sprocket shaft. Apply two drops of LOCTITE
THREADLOCKER 262 (red) to the threads of bolt. Install
bolt and washer (5) hand tight.

NOTE

Clutch hub mainshaft nut has left-hand threads.

Clean and prime threads of nut. Apply two drops of
LOCTITE THREADLOCKER 262 (red) to the threads of
the clutch hub mainshaft nut. Start nut onto mainshaft and
tighten hand tight.

NOTE

See

Figure 6-11

. When tightening the compensating sprocket

bolt, the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) must be placed between the teeth of the engine and
clutch sprockets.

Tighten compensating sprocket bolt to 155-165 ft-
lbs (210.1-223.7 Nm). Remove primary drive locking tool.

NOTE

See

Figure 6-12

. When tightening the clutch hub mainshaft

nut the PRIMARY DRIVE LOCKING TOOL (Part No. HD-
47977) must be placed between the teeth of the engine and
clutch sprockets.

Tighten clutch hub mainshaft nut to 70-80 ft-lbs (94.9-108.5
Nm). Remove primary drive locking tool.

See

Figure 6-13

. Install release plate (5) with locknut (2)

and adjuster screw (3) into clutch hub bore. The word
"OUT" stamped on the release plate should face outward.

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)

Inspect retaining ring (4) and replace if necessary. Install
retaining ring in clutch hub bore to lock release plate in
position. Verify that the retaining ring is completely seated
in the groove.

Adjust clutch. See

1.11 CLUTCH, Adjustment

NOTE

Primary chain tensioner is non-repairable. If tensioner is worn
or damaged, assembly must be replaced.

10. See

Figure 6-14

. Although primary chain tensioner is sold

as an assembly, tensioner parts can be disassembled. If
primary chain tensioner becomes disassembled, assemble
in order shown.

11. See

Figure 6-15

. Locate end of spring rod (2) on roll pin

(3).

12. See

Figure 6-16

. Slide wedge (2) of primary chain ten-

sioner in direction of arrow until all travel is removed.

13. Push shoe (1) down until it contacts wedge. Keep tension

on shoe so wedge stays in place.

14. See

Figure 6-17

. Insert cable tie (2) as shown to hold

wedge in place. Make sure end of cable tie is located
below primary chain tensioner. If cable tie is installed this
way, it will hang below primary cover gasket surface and
serve as a reminder to remove cable tie before installing
primary cover.

NOTE

Primary chain tensioner will not complete chain adjustment
until vehicle is ridden. Vehicle must be test ridden after ten-
sioner removal/installation to ensure proper adjustment.

15. See

Figure 6-18

. Install primary chain tensioner (1) into

place. Install chain tensioner fasteners (2) and tighten to
15-19 ft-lbs (20.3-25.8 Nm). Remove cable tie.

NOTE

The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.

16. Install primary chaincase cover and fill with lubricant. See

6.2 PRIMARY CHAINCASE COVER, Installation

sm02402

Rotor

Sliding cam

Compensating sprocket

Shaft extension

Washer

Bolt

Figure 6-10. Compensating Sprocket

6-6 2008 Touring Service: Drive

sm02403

Bolt

Primary drive locking tool

Figure 6-11. Installing Compensating Sprocket Bolt

sm02405

Primary drive locking tool

Mainshaft nut

Figure 6-12. Installing Clutch Hub Mainshaft Nut

sm02409

Diaphragm spring

Locknut

Adjuster screw

Retaining ring

Release plate

Figure 6-13. Clutch

2008 Touring Service: Drive 6-7

sm02410

Shoe assembly

Wedge

Washer

Spring

Spring rod

Figure 6-14. Primary Chain Tensioner Assembly

sm02411

Shoe

Spring rod

Roll pin

Figure 6-15. Spring Rod Location

sm02412

Shoe

Wedge

Figure 6-16. Primary Chain Tensioner

sm02413

Primary chain tensioner

Cable tie

Figure 6-17. Securing Primary Chain Tensioner

sm02391

Chain tensioner

Chain tensioner fasteners

Figure 6-18. Chain Tensioner

6-8 2008 Touring Service: Drive

6.4

PRIMARY CHAINCASE HOUSING

REMOVAL

To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)

Disconnect battery cable, negative cable only.

Remove primary chaincase cover. See

6.2 PRIMARY

CHAINCASE COVER, Removal

Remove starter. See

5.2 STARTER, Removal

Remove primary chain, clutch, and compensating sprocket.
See

6.3 DRIVE COMPONENTS, Removal

See

Figure 6-19

. Remove five sealing fasteners (5)

securing primary chaincase housing (11) to crankcase
and transmission. Discard the crankcase gasket (10) and
sealing fasteners.

sm05037

Seal

Lock ring

Bearing

Dowel pin

Sealing fastener (5)

Chain tensioner fasteners

Chain tensioner

Drain plug and o-ring

Shifter shaft bushings

10. Crankcase gasket
11. Primary chaincase housing

Figure 6-19. Primary Chaincase Housing

INSPECTION

Inspect primary chaincase for cracks or damaged gasket
surface.

Check the mainshaft bearing. Replace if bearing does not
rotate freely. Replace the lip seal. See

6.4 PRIMARY

CHAINCASE HOUSING, Mainshaft Bearing and Lip Seal

Inspect shifter shaft bushings. Replace if worn or dam-
aged. See

6.4 PRIMARY CHAINCASE HOUSING, Shifter

Shaft Bushings

MAINSHAFT BEARING AND LIP SEAL

Removal

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)

Pull lip seal from bearing bore on transmission side of
primary chaincase. Use a seal remover or rolling head pry
bar for best results.

Remove retaining ring from groove on transmission side
of bearing.

Support inner primary chaincase on transmission side of
bearing.

NOTE

Support inner primary chain case area on transmission side
while pressing bearing out of primary chaincase. The force
needed to remove bearing may cause damage to primary chain
case.

Place primary chaincase in arbor press. Press out bearing
from clutch side applying pressure to the outer race.

Installation

Inspect the bearing bore to verify that it is clean and
smooth. Install retaining ring in groove on pulley side of
primary chaincase.

Place primary chaincase in arbor press with the transmis-
sion side up.

Support the bearing support area on the clutch side of the
primary chaincase.

NOTE

Support the bearing support area on clutch side while pressing
bearing into bore. The force needed to press bearing into
position may force and unsupported primary chain case to
become damaged.

Apply a thin film of oil to outer diameter of bearing

Applying pressure to the outer race, press new bearing
letter side up, into bore until it makes solid contact with
the bearing support area.

See

Figure 6-20

. Retaining ring (1) must be oriented as

shown to prevent blocking of oil passage (2). Install
retaining ring to lock position of bearing in bore. Verify that
the ring is fully seated in the groove and is in proper orient-
ation.

2008 Touring Service: Drive 6-9

NOTES

•

The lip garter spring side of the oil seal is also identified
by the words "OIL SIDE".

•

Install oil seal with a seal driver that will press only against
outer rim of oil seal, NOT against the inner area.

•

The minimum allowable depth of the seal is reached when
the outer edge of the seal carrier is flush with the machined
surface of the primary housing. The maximum allowable
depth of the seal is reached when the seal carrier contacts
the mainshaft bearing snap ring.

Install mainshaft oil seal:

Lubricate the O.D. of the new seal with clean engine
oil.

See

Figure 6-21

. With the lip garter spring side

(stamped "oil side") facing toward the bearing, press
squarely on the outer edge of a new oil seal until outer
edge of seal is flush with machined surface of inner
primary housing.

Lubricate the bearing and seal lip with multi-purpose
grease or clean engine oil.

sm02385

Retaining ring

Oil passage

Figure 6-20. Retaining Ring Orientation

sm02387

Figure 6-21. Oil Seal

MAINSHAFT BEARING INNER RACE

TOOL NAME

PART NUMBER

MAINSHAFT BEARING INNER RACE
REMOVER/INSTALLER

HD-34902-B

Removal

NOTE

The bearing inner race must be positioned on the shaft a pre-
cise distance to properly align with the bearing outer race in
the primary chaincase. To remove and install the bearing inner
race, use the combination MAINSHAFT BEARING INNER
RACE REMOVER/INSTALLER (Part No. HD-34902-B).

See

Figure 6-22

. Install washers (5) on bolts (2). Slide one

bolt into channel on each side of bridge (4) so that washer
is between bridge and bolt head.

Thread bolts into stamped side of puller plate (7) an equal
number of turns.

Apply graphite lubricant to threads of forcing screw (6).
Thread forcing screw into bridge.

Position puller plate between inner race (1) and sprocket
nut.

Install end cap into end of mainshaft. Thread forcing screw
into bridge until the forcing screw seats in the end cap.
Continue turning forcing screw until the bearing inner race
is free of the mainshaft.

sm03012

Bearing inner race

Bolt (2)

End cap

Bridge

Washer (2)

Forcing screw

Puller plate

Figure 6-22. Pulling Mainshaft Inner Bearing Race

Installation

See

Figure 6-24

. Slide bearing inner race (1), chamfer

edge first, onto mainshaft.

NOTE

Extension shaft has left-hand threads.

6-10 2008 Touring Service: Drive

Thread extension shaft (2) onto end of mainshaft .

Position installer sleeve (4) over extension shaft and
against bearing inner race. Apply graphite lubricant to
threads of extension shaft.

Place two washers (5) over threaded portion of extension
shaft and install nut.

Tighten nut (6) while holding extension shaft stationary
with wrench on flats (3) at end of screw threads. Press
race onto shaft so inside edge is 0.100-0.125 in. (2.540-
3.180 mm) from main drive gear.

Lubricate race with primary chaincase lubricant.

sm03454

Figure 6-23. Mainshaft Bearing Inner Race Installer

sm03455

Bearing inner race

Extension shaft

Wrench flat

Installer sleeve

Washers

Nut

Figure 6-24. Installing Bearing Race

SHIFTER SHAFT BUSHINGS

See

Figure 6-25

. Press out old bushings (1) using an arbor

press. Inspect the bushing bore to verify that it is clean
and smooth.

Press new bushings into each side of the bore using an
arbor press. Installed bushing must be flush to 0.010
in. (0.25 mm) below edge of bore.

2008 Touring Service: Drive 6-11

Content .. 37 38 39 40 ..