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 6-4

. Remove retaining ring (4). Lift inner ramp

(5) and ramp coupling (3) out of clutch release cover.
Disconnect clutch cable end (2) from the ramp coupling
(3).

Remove coupling (3) from inner ramp.

See

Figure 6-5

. Remove balls (4) and outer ramp (2).

Unscrew clutch cable fitting from clutch release cover.

sm03007

Figure 6-3. Cover Screws

sm03008

Cable fitting

Clutch cable end

Ramp coupling

Retaining ring

Inner ramp

Retaining ring opening

Figure 6-4. Clutch Cable Connection

sm03009

Inner ramp

Outer ramp

Outer ramp tab

Balls (3)

Ramp coupling

Figure 6-5. Coupling and Ramp Assembly

HOME

6-6 2009 Dyna Service: Transmission

CLEANING AND INSPECTION

See

Figure 6-6

. Wash the ball and ramp mechanism

components in cleaning solvent.

Inspect the three balls (2) and ball socket surfaces on
ramps (1, 3) for wear, pitting, surface breakdown and other
damage. Replace damaged parts.

Check fit of the ramp coupling (4) on inner ramp (1).
Replace both parts if there is excessive wear.

Inspect the retaining ring (6) for damage or distortion.

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.

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.

sm03010

Inner ramp

Balls (3)

Outer ramp

Ramp coupling

Clutch release cover

Retaining ring

Gasket

Tab

Figure 6-6. Release Mechanism Assembly

ASSEMBLY AND INSTALLATION

NOTE

Replace cable fitting O-ring if damaged or deformed.

See

Figure 6-4

. Apply a drop of Loctite Threadlocker 243

(blue) to the clutch cable fitting (1) and install into clutch
release cover. Do not tighten at this time.

See

Figure 6-6

. Place outer ramp (3) with ball socket side

up in clutch release cover. Be sure tab (8) is in clutch
release cover slot.

Apply a multi-purpose grease to the balls and outer ramp
sockets. Place a ball in each of the outer ramp sockets.

See

Figure 6-4

. 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.

Install retaining ring (4).

Verify that two dowel pins are in place on transmission
side door flange. Place a new gasket on dowel pins.

NOTE

See

Figure 6-3

. Clutch release cover screws in positions (1)

and (6) are shorter than the others.

See

Figure 6-3

. Install clutch release cover. Tighten screws

to 84-108 in-lbs (9.5-12.2 Nm) in sequence shown.

Tighten clutch cable fitting to 90-120 in-lbs (10.2-13.6
Nm).

Fill transmission to proper level with fresh transmission
fluid. See

1.11 TRANSMISSION LUBRICANT, Changing

Transmission Lubricant

10. Adjust clutch cable. See

1.12 CLUTCH

11. Install exhaust system if removed. See

4.17 EXHAUST

SYSTEM

12. Install maxi-fuse.

HOME

2009 Dyna Service: Transmission 6-7

6.6

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

6.8 TRANSMISSION CASE

Remove exhaust system. See

4.17 EXHAUST SYSTEM

Relieve drive belt tension. See

1.14 REAR BELT

DEFLECTION

Remove primary chaincase cover, clutch assembly,
primary chain, compensating sprocket assembly and
primary chaincase. See

5.5 PRIMARY CHAINCASE

HOUSING, Removal

Remove the bearing inner race from the transmission
mainshaft. See

5.5 PRIMARY CHAINCASE HOUSING,

Mainshaft Bearing Inner Race

Remove the clutch release cover from the transmission
side door. See

6.5 CLUTCH RELEASE COVER, Removal

and Disassembly

See

Figure 6-7

. Remove oil slinger assembly from main-

shaft. Insert long rod through mainshaft bore and remove
push rod.

Remove transmission top cover, leaving the cover gasket
in place.

See

Figure 6-8

. Rotate the shifter pawl forward enough

to raise the free end and place shifter cam pawl on top
cover gasket.

sm03013

Retaining ring

Thrust washer (2)

Throw out bearing

Oil slinger

Push rod

Push rod end, left side

Figure 6-7. Push Rod Assembly

sm03011

Shifter pawl

Top cover gasket surface

Figure 6-8. Set Shifter Pawl on Gasket

NOTES

•

Only remove and install sprocket nut 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.

If main drive gear is to be removed, see

6.7 MAIN DRIVE

GEAR AND BEARING, Removal

10. See

Figure 6-9

. Remove oil spout fastener (8), oil spout

(6) and o-ring (7). Discard o-ring.

NOTE

See

Figure 6-10

. Do not 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. Cover mainshaft clutch hub splines with tape to prevent

the splines damaging the main drive gear bearings.

12. See

Figure 6-11

. Remove the transmission side door

mounting hardware. Remove exhaust bracket, if equipped.

13. Pry the side door loose and remove side door, mainshaft,

countershaft and shifter cam from transmission case as
an assembly. Discard gasket.

HOME

6-8 2009 Dyna Service: Transmission

sm03014

Locknut (2)

Spacer

Retaining ring

Bearing

Side door

Oil spout

O-ring

Oil spout fastener

Figure 6-9. Side Door Bearings

sm05040

Figure 6-10. Side Door Pry Point

sm03015

Stud

Bolt

Figure 6-11. Side Door Hardware

DISASSEMBLY

TOOL NAME

PART NUMBER

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586A

Shifter Cam/Shifter Forks

See

Figure 6-12

. 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.

Remove shift forks from dog rings.

See

Figure 6-13

. Remove lock plate fasteners (3) from

lock plate (2). Discard fasteners.

See

Figure 6-14

. Insert screwdriver and gently pry back

detent arm (4) to remove detent spring (3) tension from
shift cam (5). Remove shift cam.

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.

See

Figure 6-15

. Using dog rings, lock two gears in place.

Temporarily place transmission assembly into transmission
case.

Remove mainshaft and countershaft locknuts.

Remove transmission assembly from transmission case.

HOME

2009 Dyna Service: Transmission 6-9

sm05070

Mainshaft

Countershaft

Mainshaft 1st gear

Mainshaft 2nd gear

Mainshaft 3rd gear

Mainshaft 4th gear

Mainshaft 5th gear

Countershaft 1st gear

Countershaft 2nd gear

10. Countershaft 3rd gear
11. Countershaft 4th gear
12. Countershaft 5th gear
13. Countershaft 6th gear
14. Screw extractor

Figure 6-12. Gear Set

sm03600

Side door

Lock plate

Lock plate fastener (2)

Shift cam

Figure 6-13. Shift Drum

HOME

6-10 2009 Dyna Service: Transmission

sm03601

Screwdriver

Detent fastener

Detent spring

Detent arm

Shift cam

Figure 6-14. Detent Assembly

sm03017

Retaining ring (2)

Bearing (2)

Mainshaft locknut

Countershaft locknut

Figure 6-15. Side Door Locknuts

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.

See

Figure 6-16

. 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.

Place transmission assembly in arbor press and press
mainshaft out of side door bearings.

sm03599

Retaining ring pliers

Guiding hub

Dog ring

Mainshaft 5th gear

Figure 6-16. Mainshaft Retaining Ring

HOME

2009 Dyna Service: Transmission 6-11

sm03019

27.

14.

Mainshaft 2nd gear

Bearing

Spacer

28.

15.

Countershaft 1st gear

Mainshaft 1st gear

Lock ring

16.

29.

Securing segment (2)

Bearing

Mainshaft 5th gear

30.

17.

Dog ring

31.

18.

Lock ring

Guiding hub

19.

32.

Countershaft 4th gear

Securing segment (2)

Retaining ring

33.

20.

Retaining ring

Bearing

Guiding hub

34.

21.

Countershaft 2nd gear

Main drive gear bearing (2)

Countershaft 5th gear (part of
countershaft)

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 6-17. Mainshaft and Countershaft Assembly

HOME

6-12 2009 Dyna Service: Transmission

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.

Press countershaft out of side door bearings.

See

6.6 TRANSMISSION ASSEMBLY, Disassembly

Replacing Side Door Bearings for side door bearing
replacement.

See

Figure 6-18

. Remove washer (1), countershaft 1st

gear (2) and bearing.

NOTE

See

Figure 6-19

. Note the direction that the 2nd gear locking

ring is installed.

Remove countershaft 2nd gear lock ring.

See

Figure 6-20

. Remove securing segments (1). Remove

dog ring (3), guiding hub (2), countershaft 2nd gear (4)
and bearing.

sm03020

Washer

Countershaft 1st gear

Figure 6-18. Countershaft 1st Gear

sm03021

Figure 6-19. Lock Ring

sm03022

Securing segment

Guiding hub

Dog ring

Countershaft 2nd gear

Figure 6-20. Securing Segment

NOTE

See

Figure 6-21

. Note the direction that the 3nd gear locking

ring is installed.

Remove countershaft 3rd gear lock ring.

See

Figure 6-22

. Remove securing segments (1), internal

spline washer (2), countershaft 3rd gear (3) and bearing.

NOTE

See

Figure 6-23

. Note the direction that the 4th gear locking

ring is installed.

Remove 4th gear lock ring (1), securing segments, dog
ring (3), guiding hub (2), and countershaft 4th gear (4) and
bearing.

HOME

2009 Dyna Service: Transmission 6-13

NOTE

As countershaft 5th gear and 6th gear are an integral part of
the shaft, damage to either gear requires countershaft
replacement.

sm03023

Figure 6-21. Third Gear Lock Ring

sm03024

Securing segment

Internal spline washer

Countershaft 3rd gear

Figure 6-22. Countershaft Third Gear

sm03025

4th gear lock ring

Guiding hub

Dog ring

Countershaft 4th gear

Figure 6-23. 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)

See

Figure 6-24

. Remove the retaining rings (2).

Press the bearings out of the side door.

HOME

6-14 2009 Dyna Service: Transmission

sm02582

Locknut (2)

Retaining ring (2)

Bearing (2)

Side door

Side door gasket

O-ring

Transmission dipstick

Transmission case

Figure 6-24. Side Door Bearings

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)

Clean all parts with solvent. Blow parts dry with low pres-
sure compressed air.

Check gear teeth for damage. If gears are pitted, scored,
rounded, cracked or chipped, they should be replaced.

Inspect the engaging dogs and pockets on the dog rings.
Replace the dog rings if dogs and/or pockets are rounded,
battered or chipped.

Inspect guiding hubs. Replace guiding hubs if splines are
rounded, battered or chipped.

Inspect shift fork shafts. Replace if bent or damaged.

Inspect shift forks for wear or signs of overheating.
Replace a shift fork if it is excessively worn or shows signs
of overheating.

See

Figure 6-25

. 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.

Inspect shift drum and bearing. Replace shift drum
assembly if drum or bearing are damaged.

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 6-25. 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.

Support the door from the opposite side at the bearing
bores with a flat plate.

Position new bearing over bore with number side UP.

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)

See

Figure 6-24

. Install beveled retaining ring (2) with the

flat side next to the bearing.

HOME

2009 Dyna Service: Transmission 6-15

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 2nd, 3rd, and 4th gear lock rings have a
waved, stepped face. The waved, stepped face always
faces the securing segments.

See

Figure 6-23

. Install new needle bearing, countershaft

4th gear (4), guiding hub (2), dog ring (3) securing seg-
ments and internal splined washer (1) on countershaft.

See

Figure 6-22

. Install new needle bearing, countershaft

3rd gear (3), internal spline washer (2) and securing seg-
ments (1).

See

Figure 6-21

. 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

See

Figure 6-20

. Install new needle bearing, countershaft

2nd gear (4), guiding hub (2), dog ring (3) and securing
segments (1) on countershaft.

See

Figure 6-19

. Place lock ring over securing segments

with the stepped face of the lock ring against the securing
segments.

See

Figure 6-18

. 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.

See

Figure 6-26

. 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 6-26. Installing Countershaft

Mainshaft

NOTES

•

Failure to press on inner bearing race while pressing
bearing on the shaft will damage the bearing.

•

See

Figure 6-27

. 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.

Place mainshaft in an arbor press, supporting mainshaft
4th gear.

Place rear side door bearing over mainshaft. Using a
suitable socket, press on inner bearing race until side door
bearing contacts mainshaft 1st gear.

See

Figure 6-16

. With side door on end (shafts pointing

upward), install new bearing and mainshaft 5th gear (4).

Be sure guiding hub counterbore is facing mainshaft 5th
gear and install guiding hub (2) and dog ring (3).

Install new retaining ring using TRANSMISSION SHAFT
RETAINING RING PLIERS (Part No. J-5586A) (1).

HOME

6-16 2009 Dyna Service: Transmission

sm02860

Figure 6-27. Raise and Hold Dog Ring

Shifter Cam/Shifter Forks

Using dog rings, lock two gears in place. Temporarily place
transmission assembly into transmission case.

Install new nuts on mainshaft and countershaft. Tighten
nuts to 55-65 ft-lbs (74.6-88.2 Nm).

Remove transmission assembly from case.

Place side door on bench with shafts pointing upward.

If removed, install detent arm assembly:

See

Figure 6-28

. Clean detent screw mounting hole

in transmission side door.

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).

See

Figure 6-29

. Using screwdriver (1), pull detent arm

back to allow installation of shift cam assembly.

Install shift cam assembly (5).

See

Figure 6-30

. Install lock plate (2) and new lock plate

fasteners (3). Tighten fasteners to 57-63 in-lbs (6.4-7.1
Nm).

See

Figure 6-31

. The forks are different from each other

and are identified as shown.

10. See

Figure 6-32

. 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
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

6.7 MAIN

DRIVE GEAR AND BEARING

sm03018

Detent screw

Detent arm

Sleeve

Detent spring

Figure 6-28. Detent Assembly

sm03601

Screwdriver

Detent fastener

Detent spring

Detent arm

Shift cam

Figure 6-29. Detent Assembly

HOME

2009 Dyna Service: Transmission 6-17

sm03600

Side door

Lock plate

Lock plate fastener (2)

Shift cam

Figure 6-30. Shift Drum

sm03028

Long shift shaft

5th and 6th gear shifter fork

Short shift shaft

3rd and 4th gear shifter fork

1st and 2nd gear shifter fork

Figure 6-31. Shifter Forks and Shafts

HOME

6-18 2009 Dyna Service: Transmission

sm03029

Long shift shaft

5th and 6th gear shifter fork

5th gear

Short shift shaft

4th gear

3rd and 4th gear shifter fork

3rd gear

2nd gear

1st and 2nd gear shifter fork

10. 1st gear

Figure 6-32. Transmission Gears and Shifter Forks

INSTALLATION

Cover mainshaft clutch hub splines with tape to prevent
the splines damaging the main drive gear oil seal.

Verify that two ring dowels are in place on side door flange.
place a new gasket on the ring dowels.

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.

Install the transmission assembly in the transmission case.

If equipped, place exhaust bracket into position. Install
side door fasteners.

See

Figure 6-33

. Using crosswise pattern, tighten all side

door hardware (1, 2) to 13-18 ft-lbs (17.6-24.4 Nm).

sm03015

Stud

Bolt

Figure 6-33. Side Door Hardware

Install mainshaft bearing inner race. See

5.5 PRIMARY

CHAINCASE HOUSING, Mainshaft Bearing Inner Race

See

Figure 6-7

. Install push rod assembly (items 2-5) in

mainshaft hole. Secure with new retaining ring (1) if
removed.

NOTE

The two top side cover fasteners are shorter in length than the
others.

Install the clutch release cover, using a new gasket. See

6.5 CLUTCH RELEASE COVER

10. Remove shifter cam pawl from top cover gasket surface

and place on shift cam. Install new transmission top cover
gasket. Install transmission top cover. Install top cover
fasteners and tighten to 84-132 in-lbs (9.5-14.9 Nm).

11. Install vent hose to top cover fitting, if removed.

12. See

Figure 6-24

. Install new o-ring (7) on oil spout (6).

Apply clean engine oil to o-ring. Push oil spout into trans-
mission case. Install oil spout fastener (8). Tighten fastener
to 84-132 in-lbs (9.5-14.9 Nm).

13. Install transmission sprocket nut. See

5.7 TRANSMISSION

SPROCKET

14. Install primary chaincase, clutch assembly and primary

cover. See

5.3 PRIMARY CHAINCASE COVER, Installa-

tion

15. Replace o-ring on plug. Clean and install transmission

drain plug. Tighten to 14-21 ft-lbs (19.0-28.5 Nm).

16. Fill transmission to proper level with fresh transmission

fluid. See

1.11 TRANSMISSION LUBRICANT

17. Install exhaust system. See

4.17 EXHAUST SYSTEM

HOME

2009 Dyna Service: Transmission 6-19

6.7

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

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.

Remove the exhaust system. See

4.17 EXHAUST

SYSTEM

Remove the primary chaincase cover, clutch assembly,
primary chain, compensating sprocket, and primary
chaincase. See

5.5 PRIMARY CHAINCASE HOUSING

Remove the bearing inner race from the transmission
mainshaft. See

5.5 PRIMARY CHAINCASE HOUSING,

Mainshaft Bearing Inner Race

Remove the transmission side door. See

6.6 TRANSMIS-

SION ASSEMBLY

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).

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.

See

Figure 6-34

. 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).

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.

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.

•

See

Figure 6-35

. 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.

Remove tool and remove gear from gearcase.

10. See

Figure 6-35

. 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

Figure 6-36

. 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.

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6-20 2009 Dyna Service: Transmission

sm03033

Cross plate

Screw (2)

12 in. bolt

Main drive gear

Washer

Nice bearing

Flat washer

Nut

Figure 6-34. Removing Main Drive Gear

sm03034

Main drive gear

Long bolt (2)

Wedge attachment

Press ram

Figure 6-35. Removing Inner Bearing Race From Main Drive

Gear

sm03035

8 in. Bolt

Bearing driver

Pilot

Main drive gear bearing

Receiver cup

Nice bearing

Flat washer

Nut

Figure 6-36. Removing Main Drive Gear Bearing

CLEANING AND INSPECTION

TOOL NAME

PART NUMBER

MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL

HD-47932

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.

Inspect the main drive gear for pitting and wear. Replace
if necessary.

Inspect the needle bearings inside the main drive gear.
Replace the needle bearings if the mainshaft race is pitted
or grooved.

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2009 Dyna Service: Transmission 6-21

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