Harley Davidson 2013 Sportster Models. Service Manual

3.19

CRANKCASE

GENERAL

When replacing the connecting rod and flywheel assembly,
the pinion shaft bearing, or the sprocket shaft bearing, inspect
and make repairs to the cylinder heads, the cylinders, the gear
case and the transmission. Perform a complete engine over-
haul.

NOTE

When engine is removed from chassis, do not lay engine on
primary side. Laying engine on primary side will damage the
clutch cable end fitting. If fitting is damaged, clutch cable must
be replaced.

DISASSEMBLY

TOOL NAME

PART NUMBER

CRANKCASE BEARING
REMOVER/INSTALLER WITH
ADAPTER

B-45655, HD-42720-
2, HD-46663

SNAP-ON BODY DENT PULLER

CJ 114

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586-A

Disassemble crankcase, see

3.17 BOTTOM END OVER-

HAUL: DISASSEMBLY, Crankcase

NOTE

Remove either the pinion shaft bearing or the left main bearing
with this procedure.

See

Figure 3-121

. Pinion shaft bearing assembly (3) will

remain on pinion shaft (2) when flywheel assembly (1) is
removed from right crankcase. Using TRANSMISSION
SHAFT RETAINING RING PLIERS (Part No. J-5586-A),
remove retaining ring (4) and slip bearing off pinion shaft.

sm06555

1. Flywheel assembly
2. Pinion shaft
3. Pinion shaft bearing assembly
4. Retaining ring

Figure 3-121. Removing Pinion Shaft Bearing Retaining

Ring

NOTE

The sprocket shaft inner race is not replaceable. Replace
crankshaft if race is worn or damaged.

See

Figure 3-122

. Remove outer left main bearing

retaining ring.

Remove left main oil seal from left crankcase using SNAP-
ON BODY DENT PULLER (Part No. CJ 114).

Remove thrust washer next to left main bearing.

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2013 Sportster Service: Engine 3-93

sm01491a

Figure 3-122. Removing Left Main Oil Seal Retaining Ring

See

Figure 3-123

. Remove left main bearing retaining ring

from the inside of the left crankcase.

NOTE

Press the left main bearing from the outside of the left crank-
case toward the inside. A shoulder in the left crankcase pre-
vents the bearing from being pressed towards the outside.

See

Figure 3-124

. Using CRANKCASE BEARING

REMOVER/INSTALLER WITH ADAPTER (Part No. B-
45655, HD-42720-2, HD-46663), press left main bearing
out of the left crankcase.

Place support tube (1) on press bed with recessed
cup end facing up.

With the outboard side of the left crankcase (2) facing
upward, position crankshaft bearing bore (3) over
support tube.

Place adapter (4) over left main bearing. Insert
pilot/driver (5) through adapter, through left main
bearing and into support tube.

Carefully apply pressure with press ram (6) until left
main bearing drops free.

sm01503a

Figure 3-123. Removing Left Main Bearing Retaining Ring

sm01494a

1. Support tube
2. Left crankcase
3. Crankshaft bearing bore
4. Adapter
5. Pilot/driver
6. Press ram

Figure 3-124. Removing Left Main Bearing from Crankcase

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3-94 2013 Sportster Service: Engine

FITTING PINION BEARINGS

TOOL NAME

PART NUMBER

END CAP

HD-34902-7

FORCING SCREW

J-21686-12

BRIDGE

J-7830-5

BEARING SEPARATOR

SNAP-ON TOOLS
STOCK NO. CJ950

Outer and Inner Races

The outer race is a pressed-in bushing in the right crankcase.
The inner race is pressed on the pinion shaft.

See

Figure 3-125

. To remove pinion shaft inner race, use

BEARING SEPARATOR (Part No. Snap-on Tools Stock No.
CJ950), three items from END CAP (Part No. HD-34902-7),
BRIDGE (Part No. J-7830-5) and FORCING SCREW (Part
No. J-21686-12), and two bolts. Apply heat to race to aid
removal.

sm01495b

1. Forcing screw
2. Bridge
3. End cap
4. Bolts (2)
5. Bearing separator
6. Flywheel support fixture

Figure 3-125. Pulling Pinion Shaft Inner Bearing

Pinion bearing selection is based on the largest measured
outside diameter (OD) of the inner race and the smallest
measured inside diameter (ID) of the outer race (crankcase
bushing).

A running clearance of 0.0002-0.0008 in (0.005-0.020 mm) is
established during crankcase set or flywheel assembly
replacement and engine rebuild.

See

Figure 3-126

. Installed inner races are identified at the

factory as shown.

See

Figure 3-128

. Outer races are identified at the factory as

shown.

NOTE

The different sizes of crankcase sets and flywheel assemblies
do not have separate part numbers. Replacement crankcase
sets can have a class 1, 2 or 3 pinion outer race. Replacement
flywheel assemblies can have either a class A or B inner race.

sm01497a

1. Paint dot
2. Inner race

Figure 3-126. Factory Inner Race Sizes

Table 3-35. Inner Race Specifications

IDENTIFICATION*

CLASS

RACE OD

White

31.745-31.750

1.2498-1.2500

Green

31.740-31.745

1.2496-1.2498

* Paint dot on end of spline.

Bearing Selection

See

Figure 3-127

. Pinion bearing roller OD cannot be measured

to required accuracy with a micrometer. Select bearings using
the identification information given for inner and outer races
and bearings. Refer to

Table 3-38

NOTE

If either inner or outer race show wear, measure both races to
confirm correct bearing fit of 0.0002-0.0008 in (0.005-0.020
mm). The service wear limit of the outer race ID is 1.5656 in
(39.776 mm).

sm03413

Figure 3-127. Bearing Roller OD (A)

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2013 Sportster Service: Engine 3-95

Table 3-36. Roller Specifications

IDENTIFICATION

(PACKAGE COLOR)

ROLLER OD (A)

Red

Largest

Blue

White (gray)

Green

Smallest

Table 3-37. Outer Race Specifications

STAMPED

IDENTIFICATION*

CLASS

NO.

RACE ID

39.741-39-746

1.5646-1.5648

39.746-39.751

1.5648-1.5650

39.751-39.756

1.5650-1.5652

* Stamped number inside crankcase near race.

sm03412

1. Outer race
2. Stamped class no.
3. Right crankcase

Figure 3-128. Factory Outer Race Sizes

Table 3-38. Pinion Shaft Bearing Selection

BEARING SIZE AS IDENTIFIED BY COLOR CODING

OUTER RACE ID

FACTORY

STAMPED

NUMBER

Red

39.761-39.766

1.5654-1.5656

Blue

Red

39.756-39.761

1.5652-1.5654

White-gray

Blue

Red

39.751-39.756

1.5650-1.5652

Green

White-gray

Blue

39.746-39.751

1.5648-1.5650

Green

White-gray

39.741-39.746

1.5646-1.5648

1.2500-1.2502

1.2498-1.2500

1.2496-1.2498

Inner Race OD (in)

31.750-31.755

31.745-31.750

31.740-31.745

Inner Race OD (mm)

White

Green

Factory Color Code

NOTE

Removal and installation of the inner and outer bearing races
require the use of shop-made tools. See

Figure 3-130

Figure 3-131

, and

Figure 3-132

Measure ID of outer race at four places with a dial bore
gauge. Take measurement on ID where bearing rollers
ride. Record the four measurements.

Table 3-39. Used Pinion Bearing Outer Race Specifications

ITEM

39.776

1.5656

Largest ID allowed

0.005

0.0002

Roundness of ID (within)

0.005

0.0002

Taper (within )

If the largest measurement is larger than 1.5656 in (39.776
mm) or the required lapping to remove wear marks would
enlarge bore beyond 1.5656 in (39.776 mm), continue at
Step 8. Refer to

Table 3-39

If the largest measurement is 1.5656 in (39.776 mm) or
less, cover the cam bearings with masking tape to prevent
debris from entering bearings. Assemble crankcase halves.

NOTE

The next step requires lapping the outer race. To keep sprocket
shaft and pinion shaft bearings aligned, support the lap by an
adaptor or pilot in the left crankcase.

Lap the outer race. The race must be lapped until all wear
marks are removed. See

3.19 CRANKCASE, Lapping

Engine Main Bearing Races

After lapping race, again measure ID of race at four places
and record the measurements.

Check measurements against the specifications listed in

Table 3-39

If lapping increased bore ID to larger than 1.5656 in
(39.776 mm), go to next step. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.

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3-96 2013 Sportster Service: Engine

NOTE

Always use the smallest outer race ID measurement and the
largest OD inner race measurement when selecting bearings.

Press the outer race from the right crankcase. Press

new

outer race into crankcase flush with inside edge of cast-in
insert.

The

new

outer race must be lapped slightly to true and

align with left case bearing to specifications. Refer to

Table 3-40

. See

3.19 CRANKCASE, Lapping Engine Main

Bearing Races

Table 3-40. New Pinion Bearing Outer Race Fit and Finish

SPECIFICATION

ITEM

39.741-39.756

1.5646-1.5652

0.005

0.0002

Roundness within:

0.005

0.0002

Taper within:

16 RMS

Surface finish

10. See

Figure 3-125

. Pull inner race from pinion shaft using

BEARING SEPARATOR (Part No. Snap-on Tools Stock
No. CJ950), three items from END CAP (Part No. HD-
34902-7), BRIDGE (Part No. J-7830-5) and FORCING
SCREW (Part No. J-21686-12), and two bolts. Apply heat
to race to aid removal.

11. See

Figure 3-129

. Press

new

inner race on pinion shaft

using shop-made tool. When the tool bottoms against the
flywheel, the correct inner race location is automatically
established. The

new

inner race must be machined to

dimension based on the finished lapped ID of the outer
race. Refer to

Table 3-38

Table 3-41. Inner Race Fit and Finish

SPECIFICATION

ITEM

0.005

0.0002

Roundness within:

0.005

0.0002

Taper within:

16 RMS

Surface finish

sm03414

1. Pinion shaft inner race
2. Flywheel (gear side)
3. 1.135-1.145 in (28.83-29.08 mm)

Figure 3-129. Inner Race Location

Inner Bearing Finish Example

The following example illustrates how to determine the required
inner race OD:

If smallest measured ID of outer race is 1.5651 in (39.754
mm), an inner race OD range of 1.2496-1.2504 in (31.740-
31.760 mm) is required. Refer to

Table 3-38

NOTE

Have machinist precision grind outer race to center or middle
of required OD range. This will prevent grinding outer race
undersize and gives a more easily achieved tolerance range.

Precision grind inner race OD to the middle of the desired
range. Refer to

Table 3-38

Measure OD at four places. Verify that OD is to specifica-
tion. Refer to

Table 3-41

For example purposes:

The largest measured OD of inner race after grinding
is 1.2499 in (31.747 mm) OD.

With a 1.5651 in (39.754 mm) ID outer race and a
1.2499 in (31.747 mm) OD inner race, a blue bearing
is required. Refer to

Table 3-38

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2013 Sportster Service: Engine 3-97

sm03435

1. 2.00 in (50.8 mm)
2. 1.00 in (25.4 mm)
3. 1.560 in (39.62 mm)
4. 0.187 in (4.75 mm)
5. 5/16 drill

Figure 3-130. Pinion Shaft Outer Race Installation Tool

sm03436

1. 1.70 in (43.2 mm)
2. 1.00 in (25.4 mm)
3. 1.560 in (39.62 mm)
4. 0.187 in (4.75 mm)
5. 5/16 drill

Figure 3-131. Pinion Shaft Outer Race Removal Tool

sm03437

1. 1.50 in (38.1 mm)
2. 1.00 in (25.4 mm)
3. 5.50 in (139.7 mm)
4. 1.135-1.145 in (28.83-29.08 mm)
5. 1.262-1.272 in (32.05-32.31 mm)

Figure 3-132. Pinion Shaft Inner Race Installation Tool

LAPPING ENGINE MAIN BEARING RACES

TOOL NAME

PART NUMBER

LAPPING TOOL ADAPTER

HD-46287

CRANKCASE MAIN BEARING LAP-
PING TOOL

HD-96710-40C

CRANKCASE MAIN BEARING LAP

HD-96718-87

See

Figure 3-133

. Obtain CRANKCASE MAIN BEARING

LAPPING TOOL (Part No. HD-96710-40C). Assemble
CRANKCASE MAIN BEARING LAP (Part No. HD-96718-
87) to lapping handle.

NOTE

Left main bearing must be installed in left crankcase to use
LAPPING TOOL ADAPTER (Part No. HD-46287) in the next
step. See

3.22 BOTTOM END OVERHAUL: ASSEMBLY,

Crankcase

Assemble LAPPING TOOL ADAPTER (Part No. HD-
46287) to left main bearing.

Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right).

Insert lap shaft with arbor assembled through pinion
bearing bushing and into lapping tool adapter. Tighten
arbor expansion collars using a length of 0.156 in (3.96
mm) rod as spanner until arbor begins to drag. Do not
adjust arbor snug in bushing or bushing will bell. Belling

HOME

3-98 2013 Sportster Service: Engine

3.20

OIL PUMP: XL MODELS

GENERAL

The oil pump seldom needs servicing. Check for all possible
malfunctions related to oil pressure before disassembling oil
pump.

Make sure all oil line connections are tight. Verify that lines
are not pinched or damaged.

Check level and condition of oil in tank. Pressure will be
affected if oil is diluted. In freezing weather, proper circu-

lation of oil can be affected if the oil feed line becomes
clogged with ice or sludge.

Check for a grounded oil pressure switch wire [120] or
faulty switch if oil pressure indicator light fails to go out
with engine running.

See

3.6 ENGINE LUBRICATION SYSTEM

3.24 OIL TANK

and

6.31 OIL PRESSURE SWITCH

sm03410

Retaining ring

Oil pump cover

10.

Screw w/ washer (2)

Thrust washer

11.

O-ring

Torx screw (2)

12.

Connector

Oil pump body

13.

Elbow fitting

Hose fitting

14.

Feed gerotor set

Gear shaft

15.

Gasket

Gerotor separator plate

8. Scavenge gerotor set

Figure 3-134. Oil Pump: XL Models

HOME

3-100 2013 Sportster Service: Engine

REMOVAL

NOTE

The oil pump can be removed with engine in frame and without
removing gearcase cover.

Drain oil from oil tank.

NOTE

See

Figure 3-135

. Do not remove oil pump feed fitting (2) from

the pump (1). Hold oil pump feed fitting and loosen large high
pressure hose fitting nut (3). Then remove high pressure hose
(4) from oil pump feed fitting.

See

Figure 3-135

. Remove high pressure feed hose (4)

from oil pump (1).

sm01486a

1. Oil pump
2. Oil pump feed fitting
3. High pressure hose fitting nut
4. High pressure feed hose (to oil filter)

Figure 3-135. Oil Pump Feed Hose

NOTE

See

Figure 3-134

. The oil pump is designed to be removed as

a complete assembly by removing the two long screws (2) at
opposite corners of the pump. The other two screws (3) hold
the pump together so that it may be removed and installed as
a unit.

See

Figure 3-134

. Carefully remove two screws (2) that

secure oil pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket (15).

Disconnect and tag the two remaining oil hoses from the
pump.

DISASSEMBLY

See

Figure 3-134

. Remove two Torx screws (3). Lift cover

(1) off body (12). Remove and discard O-ring (11).

Slide both pieces of feed gerotor set (6), separator plate
(7) and both pieces of scavenge gerotor set (8) off gear
shaft (14).

Remove and discard retaining ring (9). Remove thrust
washer (10) and gear shaft.

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 in cleaning solvent. Blow out holes and oil
passages with compressed air.

See

Figure 3-136

. Inspect both gerotor sets for wear.

Mesh pieces of each set together as shown.

Use a feeler gauge to determine clearance.

The SERVICE WEAR LIMIT between gerotors is
0.004 in (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.

Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.

sm03409

1. Outer gerotor
2. Inner gerotor
3. Wear limit

Figure 3-136. Gerotor Wear Limits

ASSEMBLY

TORQUE VALUE

FASTENER

7.9-9.0 Nm

70-80

in-lbs

Oil pump cover screws

NOTE

Liberally coat all moving parts with clean engine oil to lubricate
at start-up.

See

Figure 3-134

. Install gear shaft (14) through oil pump

body (12). Position thrust washer (10) over end of shaft.
Install

new

retaining ring (9) into groove in shaft.

Insert inner gerotor of the scavenge gerotor set (8) over
gear shaft.

Place outer gerotor over inner to complete scavenge set.

Position separator plate (7) into case and line up slots on
perimeter with tabs inside oil pump body.

Place feed gerotor set (6) over gear shaft.

Install a

new

O-ring (11) into groove in oil pump cover (1).

Place cover onto pump body. Install two Torx cover screws
(3). Tighten to 70-80

in-lbs

(7.9-9.0 Nm).

HOME

2013 Sportster Service: Engine 3-101

INSTALLATION

TORQUE VALUE

FASTENER

14.1-16.9 Nm

125-150

in-lbs

Oil pump to crankcase screw

11.3-13.6 Nm

100-120

in-lbs

Oil pump feed fitting

6.8-10.2 Nm

60-90

in-lbs

Oil pump high pressure feed
hose to crankcase fitting

9.6-11.8 Nm

85-105

in-lbs

Oil pump high pressure feed
hose fitting nut

See

Figure 3-134

. Place

new

mounting gasket (15) in

position.

Secure pump to crankcase with two screws (2). Tighten
to 125-150

in-lbs

(14.1-16.9 Nm).

NOTE

Use new hose clamps to secure oil tank feed hose and vent
hose to oil pump fittings. If fittings were removed, use TEFLON
PIPE SEALANT or HYLOMAR on fitting threads.

Install hoses on oil pump. Attach oil tank feed hose to hose
fitting (5) with

new

clamp. Attach oil tank vent hose to

elbow fitting (13) with

new

clamp.

See

Figure 3-135

. If oil pump feed fitting (2) was removed

for any reason, install fitting in oil pump (1) cover. Tighten
to 100-120

in-lbs

(11.3-13.6 Nm).

If high pressure feed hose (4), was removed completely,
install end opposite high pressure fitting nut (3) in crank-
case. Tighten to 60-90

in-lbs

(6.8-10.2 Nm).

Install high pressure feed hose fitting nut (3) onto feed fit-
ting on front of oil pump. Hold oil pump feed fitting with a
wrench and tighten high pressure hose fitting nut to 85-
105

in-lbs

(9.6-11.8 Nm).

Fill oil tank with proper oil. See

1.6 ENGINE OIL AND

FILTER

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3-102 2013 Sportster Service: Engine

sm05382

21.

11.

Line connector fitting, oil to
cooler

Oil pump/gearcase housing

Oil pump rotor cover

12.

O-rings, rotor cover

O-ring

22.

13.

Thermostat (oil from cooler)

Check valve housing, cylinder
head oil

Retainer

23.

O-ring, internal (1 each fitting)

Plugs

14.

24.

O-ring

Bypass valve shuttle

Line connector fitting, return
oil

25.

15.

Spring, bypass valve

Fastener (2)

16.

O-ring, external (1 each fitting)

26.

Plug

O-ring

27.

17.

Plug

O-ring

Scavenge gerotor set

28.

18.

Feed gerotor set

Fastener (6)

Spring

19.

Check ball

Line connector fitting, supply
oil

20. Gasket

10. Vent line fitting

Figure 3-137. Oil Pump: XR 1200X

DISASSEMBLY

NOTE

The oil pump can be removed with engine in frame and without
removing gearcase cover.

Remove the exhaust system. See

4.14 EXHAUST

SYSTEM: XR 1200X

Drain oil from oil tank.

Place pan under oil pump to collect oil.

See

Figure 3-138

. Remove nine fasteners (1) and remove

gearcase and oil pump cover (2).

See

Figure 3-139

. Remove oil cooler rigid lines (3) from

gearcase cover. See

3.12 PRECISION COOLING

SYSTEM: XR 1200X, Oil Pump Lines

Remove six screws (1) and remove oil pump cover (2).
Discard cover O-rings.

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3-104 2013 Sportster Service: Engine

NOTE

If oil pump rotors are to be re-used, they must be installed in
the original location and orientation as when they are removed.
Failure to do so can result in accelerated wear and possible
engine failure.

See

Figure 3-140

. Wipe the oil film from the exposed sur-

faces of the rotors (1, 2) and mark each rotor using a
permanent marker to aid in reassembly.

NOTE

The surface tension of the remaining oil film will make the rotors
"stick" against the bottom of the bore. Never use a metallic tool
to remove oil pump rotors. This could result in damage requiring
rotor or gearcase cover replacement.

Grasp the outer rotor (1) of each stage and pull from
housing bore.

Remove each inner rotor (2).

10. Remove the thermostat fitting (3) and spring.

11. Remove the plug and bypass valve components (4).

12. If necessary, remove remaining line connector fittings from

gearcase cover.

13. Remove and discard all used O-rings.

sm05003a

1. Fastener (9)
2. Cover

Figure 3-138. Oil Pump Cover: XR 1200X

sm05018b

1. Cover screw (6)
2. Rotor cover
3. Oil cooler rigid lines

Figure 3-139. Oil Pump Rotor Cover: XR 1200X

sm05019

1. Outer rotor
2. Inner rotor
3. Thermostat
4. Bypass valve plug

Figure 3-140. Oil Pump: XR 1200X

CLEANING AND INSPECTION

Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.

HOME

2013 Sportster Service: Engine 3-105

See

Figure 3-141

. Inspect both gerotor sets for wear.

Mesh pieces of each set together as shown.

Use a feeler gauge to determine clearance.

The SERVICE WEAR LIMIT between gerotors is
0.004 in (0.102 mm). Replace gerotors as a set if
clearance exceeds this dimension.

Measure thickness of feed gerotors with a micrometer.
Replace gerotors as a set if they are not the same
thickness.

See

Figure 3-142

. Inspect thermostat spring for distortion

or cracks. Inspect rubber seal for damage. Replace ther-
mostat assembly as necessary.

sm03409

1. Outer gerotor
2. Inner gerotor
3. Wear limit

Figure 3-141. Gerotor Wear Limits

sm05659

Figure 3-142. Thermostat: XR 1200X

ASSEMBLY

TORQUE VALUE

FASTENER

12.2-17.6 Nm

108-156

in-lbs

Gearcase housing plug

10.2-13.6 Nm

90-120

in-lbs

Oil pump rotor cover screw:
XR 1200X

10.2-13.6 Nm

90-120

in-lbs

Gearcase cover fastener

NOTE

Used O-rings can leak. Always install new O-rings when per-
forming repairs.

Install

new

internal O-rings in each line connector fitting.

Install

new

external O-rings on all connector fittings that

have been removed.

NOTE

Apply a light coat of new engine oil to the shuttle valve compon-
ents and oil pump rotors during assembly.

See

Figure 3-140

. Install bypass valve components (4).

Tighten plug to 108-156

in-lbs

(12.2-17.6 Nm).

Install thermostat and oil cooler line fitting (3).

NOTE

If oil pump rotors are to be re-used, they must be installed in
the original location and orientation. Make sure the mark made
during disassembly is visible when installing the rotors. Failure
to do so can result in accelerated wear and possible engine
failure.

Install each outer rotor (1) in its original location.

Install each inner rotor (2) in its original location.

See

Figure 3-139

. Install

new

O-rings in oil pump rotor

cover and install cover using six fasteners (1). Tighten
fasteners to 90-120

in-lbs

(10.2-13.6 Nm).

Install oil cooler rigid lines (3) to quick connect fittings. See

3.12 PRECISION COOLING SYSTEM: XR 1200X, Oil
Pump Lines

See

Figure 3-143

. Install oil pump/cam support housing

cover. Secure with 9 socket fasteners. Tighten in the
sequence shown to 90-120

in-lbs

(10.2-13.6 Nm).

10. Install the exhaust system. See

4.14 EXHAUST SYSTEM:

XR 1200X

HOME

3-106 2013 Sportster Service: Engine

sm00294

1. Removal end of bearing tool
2. Installation end of bearing tool
3. Bearing guide, installer

Figure 5-26. Clutch Shell Bearing Remover/Installer

sm00295a

Figure 5-27. Removing Clutch Shell Needle Bearing

sm00296

1. Place needle bearing on tool in this location
2. Bearing guide

Figure 5-28. Bearing Installer

sm00297a

1. Needle bearing
2. Clutch shell

Figure 5-29. Installing Clutch Shell Needle Bearing

ASSEMBLY

TOOL NAME

PART NUMBER

SPRING COMPRESSING TOOL

HD-38515-A

Submerge and soak all friction and steel plates in
GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMIS-
SION AND PRIMARY CHAINCASE LUBRICANT for at
least five minutes.

See

Figure 5-30

. Install narrow friction plate on the clutch

hub, engaging tabs on plate with slots in clutch shell.

See

Figure 5-31

. Install damper spring seat (1) on clutch

hub so that it seats inboard of narrow friction plate (3).

HOME

5-20 2013 Sportster Service: Drive/Transmission

Install damper spring (2) on clutch hub with the concave
side up (facing opposite damper spring seat).

Install a steel plate (4) and then a friction plate (5) on the
clutch hub. Install six remaining sets in the same manner,
alternating between steel plates and friction plates.

sm00285a

1. Narrow plate
2. Regular plate

Figure 5-30. Friction Plates

Place pressure plate, diaphragm spring, adjusting screw
assembly with

new

retaining ring and spring seat onto

clutch pack.

Install the retaining ring:

See

Figure 5-32

. Align square openings of pressure

plate and diaphragm spring so that the assembly can
be installed over prongs on clutch hub.

Position spring seat with its larger outer diameter side
toward diaphragm spring.

NOTE

Turn compressing tool handle only the amount required
to install spring seat and retaining ring. Excessive com-
pression of diaphragm spring could damage clutch pres-
sure plate.

Install SPRING COMPRESSING TOOL (Part No. HD-
38515-A) onto clutch hub against diaphragm spring.

Place a wrench on the clutch spring forcing screw
flats to prevent the forcing screw from turning.

Turn compressing tool handle clockwise until dia-
phragm spring compresses just enough to install new
retaining ring into the groove in clutch hub prongs.

With retaining ring fully seated in groove of clutch
hub, remove the compression tool.

NOTE

Remove the tool to allow the diaphragm spring to move outward
forcing the spring seat up into the inside of the retaining ring.
The spring seat is an operating surface for the diaphragm
spring and prevents the retaining ring from coming out.

sm00286a

1. Damper spring seat
2. Damper spring
3. Narrow friction plate
4. Steel plate
5. Friction plate

Figure 5-31. Clutch Pack Stack-Up

sm01265a

1. Diaphragm spring (pressure plate below)
2. Prongs on clutch hub
3. Retaining ring
4. Adjusting screw assembly
5. Spring seat

Figure 5-32. Spring Seat Installation

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2013 Sportster Service: Drive/Transmission 5-21

Harley Davidson 2013 Sportster Models. Service Manual - page 39