Harley Davidson 2011 Touring Models. Service Manual - page 23

sm02386a

Figure 3-86. Rocker Arm Bolt Sequence (late production

shown)

Complete installation of the push rod covers.

Verify that the O-ring ends of the upper and lower
push rod covers fit snugly into the cylinder head and
lifter cover bores.

Insert the upper edge of spring cap retainer into the
cylinder head bore leaving the bottom edge free.

Insert blade of small screwdriver between bottom
edge of spring cap retainer and top of spring cap.

NOTE

For best results, be sure that screwdriver, spring cap and
spring cap retainer are free of grease and oil.

See

Figure 3-87

. While simultaneously depressing

spring cap with tip of screwdriver, use forefinger to
slide bottom edge of spring cap retainer down shaft
towards tip of screwdriver blade. As spring cap
reaches its full length of travel, spring cap retainer
should be in approximate position against upper push
rod cover.

Verify that spring cap retainer is seated tightly against
upper push rod cover.

sm02347

Figure 3-87. Install Spring Cap Retainers

BREATHER AND ROCKER COVER

TOOL NAME

PART NUMBER

"DOG BONE" TORQUE ADAPTER

SNAP-ON FRDH141

NOTE

For

breather

assembly

service

procedures,

see

3.19 BREATHER ASSEMBLY

To secure breather assembly, tighten two screws to 120-
156

in-lbs

(13.6-17.6 Nm).

NOTE

If the engine was left in the chassis for service, final tighten
the three rocker cover bolts on the left side of the rear cylinder
using a 3/8 in. drive torque wrench with a 7/16 in. flank drive
"DOG BONE" TORQUE ADAPTER (Part No. Snap-on
FRDH141). Failure to properly use this combination will over-
tighten the bolts causing distortion of the rocker cover.

Apply a drop of LOCTITE THREADLOCKER 243 (blue)
to threads of rocker cover screws.

See

Figure 3-88

. Install rocker cover and a

new

rocker

cover gasket. Tighten screws following the sequence
shown to 15-18 ft-lbs (20.3-24.4 Nm).

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2011 Touring Service: Engine 3-73

Complete motorcycle assembly.

If engine was left in the chassis for service, see

3.15 ASSEMBLING MOTORCYCLE AFTER SER-
VICE

engine

was

removed

for

service,

see

3.17 INSTALLING ENGINE IN CHASSIS

sm02326

1. Short bolt, 1.0 in. (25.4 mm)
2. Long bolt, 1.75 in. (44.5 mm)
3. Short bolt, 1.0 in. (25.4 mm)
4. Long bolt, 1.75 in. (44.5 mm)
5. Short bolt, 1.0 in. (25.4 mm)
6. Long bolt, 1.75 in. (44.5 mm)

Figure 3-88. Rocker Cover Bolts Torque Sequence

HOME

3-74 2011 Touring Service: Engine

3.26

CAM COMPARTMENT AND COMPONENTS

CAM SUPPORT PLATE AND COVER
REMOVAL

TOOL NAME

PART NUMBER

SCREAMIN' EAGLE MAGNETIC
LIFTER HOLDERS

93979-10

CRANKSHAFT/CAMSHAFT
SPROCKET LOCKING TOOL

HD-47941

Prepare Engine

NOTE

The following steps outline removal with the rest of the engine
intact. If performing a complete engine overhaul, perform all
steps under

3.18 TOP END OVERHAUL: DISASSEMBLY

Remove breather assembly, rocker arm support plate,
push rods and push rod covers. Do not remove lifters. See
appropriate topics under

3.18 TOP END OVERHAUL:

DISASSEMBLY

See

Figure 3-90

. Support lifters using SCREAMIN' EAGLE

MAGNETIC LIFTER HOLDERS (Part No. 93979-10).

See

Figure 3-89

. Remove the socket head screws to

release the cam cover. Remove and discard the cam cover
gasket.

NOTE

Cam cover screws are 1/4 x 1-1/4 in. while the cam support
plate, lifter cover and crankshaft position sensor screws are
1/4 x 1 in. The shorter screws are interchangeable. Use care
to keep the two lengths separate to be sure of using the correct
length during assembly.

sm02183

Figure 3-89. Cam Cover Screws

sm02510a

Figure 3-90. Screamin' Eagle Magnetic Lifter Holder

Cam Chain and Sprockets Removal

See

Figure 3-91

. Using a colored marker, mark one of the

links (1) of the primary cam chain to identify the visible
side. Maintaining the original direction of rotation during
assembly may prolong service life.

NOTE

Use a piece of wire in retention hole (6) to keep cam chain
tensioner components assembled.

Remove primary cam chain tensioner fasteners (4) and
primary cam chain tensioner (3).

NOTE

Be sure side of tool labeled "crank side" faces crankshaft
sprocket.

See

Figure 3-92

. Install CRANKSHAFT/CAMSHAFT

SPROCKET LOCKING TOOL (Part No. HD-47941)
between cam sprocket (2) and crank sprocket (5).

Be sure to follow manufacturer's instructions when using
propane

torches.

Failure

follow

manufacturer's

instructions can cause a fire, which could result in death
or serious injury. (00465c)

•

Avoid directing heat toward any fuel system com-
ponent. Extreme heat can cause fuel ignition/explosion
resulting in death or serious injury.

•

Avoid directing heat toward any electrical system
component.

NOTES

•

Only use approved methods for removing rear cam bolt.
Other methods of removal, such as the use of a large

HOME

2011 Touring Service: Engine 3-75

breaker bar, may result in damage to chain drive and other
components.

•

If necessary, soften LOCTITE by using heat from a small
propane torch. Apply flame evenly around bolt in a circular
motion, but do not allow bolt to turn blue.

Remove the rear cam sprocket bolt and flat washer (1)
from the rear cam sprocket (2).

Remove the crank sprocket bolt and flat washer (4) from
the crank sprocket (5).

Remove camshaft locking tool.

Use a small pry bar between rear cam sprocket and cam
support plate to carefully ease off rear cam sprocket until
loose on camshaft.

Use a small pry bar to ease off crank sprocket. Remove
both sprockets and primary cam chain.

sm02399

1. Link
2. Rear cam sprocket
3. Primary cam chain tensioner
4. Primary cam chain tensioner fasteners
5. Crank sprocket
6. Retention hole

Figure 3-91. Cam Support Plate Assembly

sm02401

1. Rear cam sprocket bolt (large) and flat washer
2. Rear cam sprocket
3. Camshaft locking tool
4. Crank sprocket bolt (small) and flat washer
5. Crank sprocket

Figure 3-92. Cam Support Plate Assembly

Cam Support Plate Removal

See

Figure 3-93

. Following the sequence shown, remove

four socket head screws.

See

Figure 3-94

. Following the sequence shown, remove

six socket head screws to release the cam support plate
from the crankcase.

See

Figure 3-95

. Use a small pry bar between the cam

support plate and crankcase flange in areas adjacent to
the ring dowels (2, 3) to work cam support plate and
camshafts from end of crankshaft.

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3-76 2011 Touring Service: Engine

sm02185

Figure 3-93. Oil Pump Torque Sequence

sm02404

Figure 3-94. Cam Support Plate Torque Sequence

sm02407

1. Right crankcase half
2. Forward ring dowel
3. Rear ring dowel

Figure 3-95. Ring Dowels

CAM SUPPORT PLATE CLEANING AND
INSPECTION

Oil Pressure Valve

Inspect oil pressure valve. See

3.26 CAM COMPARTMENT

AND COMPONENTS, Oil Pressure Relief Valve

Cam Support Plate

Measure the diameters of the camshaft bores and crank-
shaft bore. See

3.3 SERVICE WEAR LIMITS, General

Measure flatness of support plate. See

3.3 SERVICE

WEAR LIMITS, General

Inspect gerotor area for excessive wear or deep grooves.

Verify that all oil holes are clean and open.

NOTE

Exercise caution to avoid enlarging the oil holes or oil pressure
will be adversely affected.

CAMSHAFTS

TOOL NAME

PART NUMBER

CAMSHAFT ASSEMBLY TOOL

HD-47956

Removal

See

Figure 3-96

. Remove screws (4) and remove sec-

ondary cam chain tensioner (3).

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)

HOME

2011 Touring Service: Engine 3-77

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 Removing Side Door Bearings on the following page
for side door bearing replacement.

See

Figure 6-17

. Remove washer (1), countershaft 1st

gear (2) and bearing.

NOTE

See

Figure 6-18

. Note the direction that the 2nd gear locking

ring is installed.

Remove countershaft 2nd gear lock ring.

See

Figure 6-19

. Remove securing segments (1). Remove

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

sm03020a

1. Washer
2. Countershaft 1st gear

Figure 6-17. Countershaft 1st Gear

sm03021

Figure 6-18. Lock Ring

sm03022

1. Securing segment
2. Guiding hub
3. Dog ring
4. Countershaft 2nd gear

Figure 6-19. Securing Segment

NOTE

See

Figure 6-20

. Note the direction that the 3rd gear locking

ring is installed.

Remove countershaft 3rd gear lock ring.

See

Figure 6-21

. Remove securing segments (1), internal

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

NOTE

See

Figure 6-22

. 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

2011 Touring 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 6-20. Third Gear Lock Ring

sm03024

1. Securing segment
2. Internal spline washer
3. Countershaft 3rd gear

Figure 6-21. Countershaft Third Gear

sm03025a

1. 4th gear lock ring
2. Guiding hub
3. Dog ring
4. Countershaft 4th gear

Figure 6-22. Countershaft Assembly

Removing 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 6-23

. Remove the retaining rings (1).

Press the bearings out of the side door.

sm05071

1. Retaining ring (2)
2. Bearing (2)
3. Side door

Figure 6-23. Side Door Bearings

HOME

6-14 2011 Touring Service: Transmission

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 6-24

. 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 6-24. 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 6-23

. Install beveled retaining ring (1) with the

flat side next to the bearing.

Countershaft

NOTES

•

Replace retaining ring and all gear roller bearings with
new parts during assembly. Lubricate needle bearings
and races with Screamin' Eagle Assembly Lube (Part No.
94971-090 before installation.

•

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 6-22

. 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 6-21

. Install

new

needle bearing, countershaft

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

See

Figure 6-20

. Place countershaft 3rd gear lock ring

over securing segments.

HOME

2011 Touring Service: Transmission 6-15

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 6-19

. Install

new

needle bearing, countershaft

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

See

Figure 6-18

. Place lock ring over securing segments

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

See

Figure 6-17

. 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 6-25

. 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.

sm03027a

Figure 6-25. Installing Countershaft

Mainshaft

NOTES

•

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

•

See

Figure 6-26

. 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 6-15

. 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).

sm02860a

Figure 6-26. 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 85-95 ft-lbs (115.3-128.8 Nm).

Remove transmission assembly from case.

Place side door on bench with shafts pointing upward.

If removed, install detent arm assembly:

See

Figure 6-27

. 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 6-28

. Using screwdriver (1), pull detent arm

back to allow installation of shift cam assembly.

Install shift cam assembly (5).

See

Figure 6-29

. Install lock plate (2) and

new

lock plate

fasteners (3). Tighten fasteners to 57-63

in-lbs

(6.4-7.1

Nm).

HOME

6-16 2011 Touring Service: Transmission

See

Figure 6-30

. The forks are different from each other

and are identified as shown.

10. See

Figure 6-31

. 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

1. Detent screw
2. Detent arm
3. Sleeve
4. Detent spring

Figure 6-27. Detent Assembly

sm03601a

1. Screwdriver
2. Detent fastener
3. Detent spring
4. Detent arm
5. Shift cam

Figure 6-28. Detent Assembly

HOME

2011 Touring Service: Transmission 6-17

sm03600a

1. Side door
2. Lock plate
3. Lock plate fastener (2)
4. Shift cam

Figure 6-29. Shift Drum

sm03028

1. Long shift shaft
2. 5th and 6th gear shifter fork
3. Short shift shaft
4. 3rd and 4th gear shifter fork
5. 1st and 2nd gear shifter fork

Figure 6-30. Shifter Forks and Shafts

HOME

6-18 2011 Touring Service: Transmission

sm03029a

1. Long shift shaft
2. 5th and 6th gear shifter fork
3. 5th gear
4. Short shift shaft
5. 5th gear
6. 3rd and 4th gear shifter fork
7. 3rd gear
8. 2nd gear
9. 1st and 2nd gear shifter fork
10. 1st gear

Figure 6-31. 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
with a

new

gasket.

See

Figure 6-32

. Install exhaust bracket using long screws

(1). Install remaining side door screws (2).

See

Figure 6-33

. Tighten all side door hardware in the

sequence shown to 13-18 ft-lbs (17.6-24.4 Nm).

sm03669

1. Long screw (2)
2. Short screw (6)

Figure 6-32. Side Door hardware

sm05044

Figure 6-33. Side Door Torque Sequence

Install mainshaft bearing inner race. See

5.7 TRANSMIS-

SION SPROCKET

See

Figure 6-34

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

mainshaft hole. Secure with

new

retaining ring (1) if

removed.

Install the clutch release cover, using a

new

gasket. See

6.5 CLUTCH RELEASE COVER

10. Rotate shifter cam pawl forward and lower into place on

shift cam. Install

new

transmission top cover gasket. Install

transmission top cover. Tighten fasteners to 90-120

in-lbs

(10.2-13.6 Nm).

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

12. Install transmission sprocket nut. See

5.7 TRANSMISSION

SPROCKET

HOME

2011 Touring Service: Transmission 6-19

13. Install primary chaincase, clutch assembly and primary

cover. See

5.3 PRIMARY CHAINCASE COVER, Installa-

tion

14. Replace O-ring on plug. Clean and install transmission

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

15. Fill transmission to proper level with fresh transmission

fluid. See

1.10 TRANSMISSION LUBRICANT

16. Adjust drive belt tension. See

1.12 DRIVE BELT AND

SPROCKETS

17. Install exhaust system. See

4.19 EXHAUST SYSTEM

sm03013

1. Retaining ring
2. Thrust washer (2)
3. Throw out bearing
4. Oil slinger
5. Push rod
6. Push rod end, left side

Figure 6-34. Push Rod Assembly

HOME

6-20 2011 Touring Service: Transmission

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

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

4.19 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 6-35

. 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), 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 6-36

. 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 6-36

. 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 6-37

. 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 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.

HOME

2011 Touring Service: Transmission 6-21

sm03033

1. Cross plate
2. Screw (2)
3. 12 in. bolt
4. Main drive gear
5. Washer
6. Bearing
7. Flat washer
8. Nut

Figure 6-35. Removing Main Drive Gear

sm03034

1. Main drive gear
2. Long bolt (2)
3. Wedge attachment
4. Press ram

Figure 6-36. Removing Inner Bearing Race From Main Drive

Gear

sm03035

1. 8 in. Bolt
2. Bearing driver
3. Pilot
4. Main drive gear bearing
5. Receiver cup
6. Bearing
7. Flat washer
8. Nut

Figure 6-37. 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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6-22 2011 Touring Service: Transmission

Replace the sprocket if teeth are cracked or worn. See

5.7 TRANSMISSION SPROCKET, Cleaning and Inspec-
tion

for more information.

Inspect the needle bearings on the inside of the main drive
gear. If mainshaft race surface appears pitted or grooved,
replace these bearings.

NOTE

If the main drive gear needle bearings and/or seal need to be
replaced, continue as follows. Otherwise, proceed to

6.8 TRANSMISSION CASE, Assembly

Needle Bearing Replacement

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)

NOTES

•

See

Figure 6-39

. When replacing needle bearings, discard

original retaining rings (1) and install replacement retaining
rings (2).

•

To install the inner main drive gear needle bearings and
mainshaft seal, use MAIN DRIVE GEAR BEARING AND
SEAL INSTALLATION TOOL (Part No. HD-47932).

See

Figure 6-38

. Remove mainshaft seal (6). Remove

retaining rings (1), needle bearings (2) and spacer (5) from
main drive gear (3). Discard retaining rings.