Content .. 38 39 40 41 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 40

INSTALLATION

TOOL NAME

PART NUMBER

SPORTSTER 5-SPEED SPROCKET
LOCKING LINK

HD-38362

PRIMARY DRIVE LOCKING TOOL

HD-46283

TORQUE VALUE

FASTENER

210.0-224.0

155-165 ft-lbs

Engine sprocket bolt: XR
1200X

67.8-81.3 Nm

50-60 ft-lbs

Transmission mainshaft nut:
XR 1200X

See

Figure 5-19

. Remove retaining ring (12). Remove

adjusting screw assembly (13, 14, 15, 16) from pressure
plate (17) to allow installation of the transmission mainshaft
nut and washer.

NOTE

Prior to installing engine sprocket bolt and transmission main-
shaft nut, thoroughly clean threads of engine sprocket shaft,
transmission mainshaft and mainshaft nut to remove any oil
that might contaminate and interfere with locking agent.

Thoroughly clean threads of engine sprocket shaft, trans-
mission mainshaft and mainshaft nut to remove any oil.

NOTES

•

See

Figure 5-33

. Do not position the sprocket locking link

(1) too close to the shifter shaft (2). The sprocket locking
can damage the shifter shaft and/or engine crankcase.

•

Japan models use PRIMARY DRIVE LOCKING TOOL
(Part No. HD-46283).

See

Figure

5-33

Install

SPORTSTER

5-SPEED

SPROCKET LOCKING LINK (Part No. HD-38362) (1).

Install

new

engine sprocket bolt. Tighten to 155-165 ft-lbs

(210.0-224.0 Nm).

NOTE

See

Figure 5-34

. Washer (2) must be installed with the word

"out" facing the transmission mainshaft nut (1). Incorrect
assembly can result in clutch and/or transmission failure.

Install mainshaft nut.

See

Figure 5-34

. Apply two or three drops of LOCTITE

262 HIGH STRENGTH THREADLOCKER AND
SEALANT (red) onto threads of transmission main-
shaft.

Install spring washer (2) and mainshaft nut (1) (left-
hand threads) on transmission mainshaft.

Tighten to 50-60 ft-lbs (67.8-81.3 Nm).

Remove the sprocket locking link.

See

Figure 5-35

. Install adjusting screw assembly in

pressure plate with two tabs on perimeter of release plate
matched to recesses in pressure plate. Secure with a

new

retaining ring.

Install primary cover using

new

gasket. See

5.3 PRIMARY

COVER

Adjust primary chain and clutch. See

1.9 PRIMARY CHAIN

and

1.11 CLUTCH

10. Fill transmission. See

1.10 TRANSMISSION LUBRICANT

11. Connect battery and close left side cover. See

1.22 BAT-

TERY MAINTENANCE

sm06563

1. Sprocket locking link
2. Shifter shaft

Figure 5-33. Tighten Engine Sprocket Bolt

sm00290

1. Mainshaft nut
2. Washer
3. Clutch hub

Figure 5-34. Mainshaft Nut and Washer

HOME

5-22 2013 Sportster Service: Drive/Transmission

sm00288a

1. Adjusting screw assembly
2. Retaining ring
3. Tab recesses

Figure 5-35. Clutch Adjusting Screw Assembly and

Retaining Ring

HOME

2013 Sportster Service: Drive/Transmission 5-23

5.6

DRIVE BELT

DRIVE BELT HANDLING

See

Figure 5-36

•

Do not exceed 5 in (127 mm) forward bend (1).

•

Do not exceed 10 in (254 mm) reverse bend (2).

•

Do not twist (3).

•

Do not crimp, pinch or kink (4).

•

Do not pry (5).

sm02440a

Figure 5-36. Drive Belt Handling

DRIVE BELT: XL MODELS

TORQUE VALUE

FASTENER

40.7-44.8 Nm

30-33 ft-lbs

Exhaust pipe clamp bracket
fastener: XL Models

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

Removal

Remove

mufflers

and

rear

exhaust

pipe.

See

4.13 EXHAUST SYSTEM: XL MODELS

Mid-Mount

Controls:

Remove

right

side

rider

footrest/brake pedal and mounting bracket assembly. See

2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CON-
TROLS

See

Figure 5-37

. Remove screw (6), washer (5) and

exhaust pipe clamp bracket (4).

Remove two screws (2, 3).

See

Figure 5-38

. Remove E-clip (1). Discard E-clip.

Loosen rear axle nut (4).

Turn the axle adjuster nut (2) on each side of rear fork an
equal number of turns counterclockwise to decrease belt
tension.

Remove right lower shock absorber screw, washer and
locknut. See

2.24 SHOCK ABSORBERS, Removal

Remove the belt guard. See

2.22 BELT GUARD AND

DEBRIS DEFLECTOR, Belt Guard: XL Models

10. Remove the debris deflector. See

2.22 BELT GUARD

AND DEBRIS DEFLECTOR, Debris Deflector: XL Models

Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)

11. See

Figure 5-39

. Remove belt.

sm01356

1. Sprocket cover
2. Screw
3. Screw
4. Exhaust pipe clamp bracket
5. Washer
6. Screw

Figure 5-37. Sprocket Cover: XL Models

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5-24 2013 Sportster Service: Drive/Transmission

sm03591d

1. E-clip
2. Axle adjuster nut (2)
3. Axle adjuster (2)
4. Axle nut
5. Washer
6. Protective cap (2)

Figure 5-38. Drive Belt Adjustment: XL Models

sm07540

Figure 5-39. Drive Belt Removal: XL Models

Installation

Install belt onto sprockets.

Install the front of belt guard. See

2.22 BELT GUARD AND

DEBRIS DEFLECTOR, Belt Guard: XL Models

Install the debris deflector. See

2.22 BELT GUARD AND

DEBRIS DEFLECTOR, Debris Deflector: XL Models

Install right lower shock absorber bolt, washer and locknut.
See

2.24 SHOCK ABSORBERS, Installation

NOTE

See

Figure 5-37

. Short screw (2) goes in bottom hole. Long

screw (3) goes in top hole. Do not tighten screws.

Install sprocket cover (1). Secure with two screws.

Install exhaust pipe clamp bracket (4), washer (5) and
screw (6).

Tighten:

Exhaust pipe clamp bracket fastener 30-33 ft-lbs
(40.7-44.8 Nm)

Sprocket cover fasteners 80-120

in-lbs

(9.0-13.6 Nm)

Mid-Mount Controls:

Install right side rider footrest/brake

pedal and mounting bracket assembly. See

2.40 RIDER

FOOT CONTROLS: XL MID-MOUNT CONTROLS

Install rear exhaust pipe and mufflers. See

4.13 EXHAUST

SYSTEM: XL MODELS

10. Adjust belt tension. See

1.12 DRIVE BELT AND

SPROCKETS, Drive Belt Deflection

11. Check wheel alignment. See

1.24 WHEEL ALIGNMENT,

Wheel Alignment

12. See

Figure 5-38

. Tighten rear axle nut (4) to 95-105 ft-lbs

(129-142 Nm).

13. Install

new

E-clip (1).

IDLER PULLEY: XR 1200X

TORQUE VALUE

FASTENER

95-109 Nm

70-80 ft-lbs

Idler pulley fastener: XR
1200X

44.7-47.5 Nm

33-35 ft-lbs

Idler pulley bracket flanged
nut: XR 1200X

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover, rear screw

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

Removal

See

Figure 5-40

. Remove sprocket cover (1).

NOTE

It is not necessary to remove the drive belt completely.

Release tension from drive belt and slide belt off drive
sprocket (5). See

5.6 DRIVE BELT, Drive Belt: XL Models

NOTE

If exhaust system interference prevents removal, loosen all
exhaust system mount fasteners and flange nuts. Pull exhaust
system away from engine to allow room to remove idler
assembly.

Remove nuts (3) and washers (4). Remove idler pulley
and bracket assembly from vehicle.

Spin and check idler pulley (7) for bearing wear. See

1.12 DRIVE BELT AND SPROCKETS, Inspection

NOTE

The idler pulley bearings can not be replaced separately.

If idler pulley needs replacement, remove fastener (8) and
bushings (2). Discard idler pulley and replace with

new

idler pulley (7).

HOME

2013 Sportster Service: Drive/Transmission 5-25

sm05541

1. Sprocket cover
2. Bushing (2)
3. Flanged nut (2)
4. Washer (2)
5. Drive sprocket
6. Idler pulley bracket
7. Idler pulley
8. Fastener

Figure 5-40. Drive Belt Idler: XR 1200X

Installation

See

Figure 5-40

. Install

new

or existing idler pulley (7), if

removed. Tighten fastener (8) to 70-80 ft-lbs (95-109 Nm).

Install idler pulley and bracket assembly. Install washers
(4) and flanged nuts (3). Tighten to 33-35 ft-lbs (44.7-47.5
Nm).

Install drive belt and adjust belt tension and wheel align-
ment. See

1.24 WHEEL ALIGNMENT

Install sprocket cover:

Tighten rear (larger) screw to 30-33 ft-lbs (40.7-44.8
Nm).

Tighten forward and lower (smaller) screws to 80-120

in-lbs

(9.0-13.6 Nm).

If loosened, align. Tighten exhaust system components.
See

4.14 EXHAUST SYSTEM: XR 1200X

DRIVE BELT: XR 1200X

TORQUE VALUE

FASTENER

40.7-44.8 Nm

30-33 ft-lbs

Sprocket cover, rear screw

9.0-13.6 Nm

80-120

in-lbs

Sprocket cover, forward and
lower screws

129-142 Nm

95-105 ft-lbs

Axle, rear, nut

Removal

Remove exhaust system. See

4.14 EXHAUST SYSTEM:

XR 1200X

See

Figure 5-41

. Remove screws (2, 3, 4). Remove

sprocket cover (1).

See

Figure 5-42

. Remove E-clip. Discard E-clip (1).

Loosen rear axle nut (4).

Turn the axle adjuster nut (2) on each side of rear fork an
equal number of turns counterclockwise to release belt
tension.

Remove right lower shock absorber screw, washer and
locknut. See

2.24 SHOCK ABSORBERS, Removal

Remove belt guard. See

2.22 BELT GUARD AND DEBRIS

DEFLECTOR, Belt Guard: XR 1200X

Remove debris deflector. See

2.22 BELT GUARD AND

DEBRIS DEFLECTOR, Debris Deflector: XR 1200X

See

Figure 5-43

. Remove belt.

sm05328

1. Sprocket cover
2. Rear screw and washer
3. Front screw
4. Lower screw

Figure 5-41. Sprocket Cover: XR 1200X

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5-26 2013 Sportster Service: Drive/Transmission

sm07549

1. E-clip
2. Axle adjuster nut (2)
3. Axle adjuster (2)
4. Axle nut
5. Washer
6. Protective cap (2)

Figure 5-42. Drive Belt Adjustment: XR 1200X

sm07548

Figure 5-43. Drive Belt Removal: XR 1200X

Installation

Install belt onto sprockets.

Install belt guard. See

2.22 BELT GUARD AND DEBRIS

DEFLECTOR, Belt Guard: XR 1200X

Install debris deflector. See

2.22 BELT GUARD AND

DEBRIS DEFLECTOR, Debris Deflector: XR 1200X

Install right lower shock absorber bolt, washer and locknut.
See

2.24 SHOCK ABSORBERS, Installation

NOTE

See

Figure 5-41

. Long screw (3) goes in top hole. Short screw

(4) goes in bottom hole.

Install sprocket cover (1).

Tighten screw (2) to 30-33 ft-lbs (40.7-44.8 Nm).

Tighten screws (3, 4) to 80-120

in-lbs

(9.0-13.6 Nm).

Install exhaust system. See

4.14 EXHAUST SYSTEM: XR

1200X, Installation

Adjust belt tension. See

1.12 DRIVE BELT AND

SPROCKETS, Drive Belt Deflection

Check rear wheel alignment. See

1.24 WHEEL ALIGN-

MENT, Wheel Alignment

See

Figure 5-42

. Tighten rear axle nut (4) to 95-105 ft-lbs

(129-142 Nm). Install

new

E-clip (1).

HOME

2013 Sportster Service: Drive/Transmission 5-27

5.7

TRANSMISSION POWER FLOW

GENERAL

See

Figure 5-44

. The transmission is a five-speed constant-

mesh type housed in an extension of the crankcase. The
transmission permits the rider to vary the ratio of engine speed-
to-rear driving wheel speed in order to meet the varying condi-
tions of operation.

The transmission is foot-operated by the gear shifter lever,
which transmits the force through a gear shifter shaft. The
shifter shaft actuates a pawl and a shifter fork drum. The shifter
fork drum moves shifter forks. The shifter forks slide a series
of shifter dogs into and out of mesh with the other gears.

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5-28 2013 Sportster Service: Drive/Transmission

{

sm03353

Power flow

Mainshaft

Countershaft

Moves in

Moves out

Countershaft gears

4. Sliding member

Figure 5-44. Transmission Power Flow

HOME

2013 Sportster Service: Drive/Transmission 5-29

5.8

CASE DISASSEMBLY FOR TRANSMISSION
REMOVAL

GENERAL

The rear compartment of the left and right crankcase halves
form the transmission case. Servicing of transmission compon-
ents requires removing the engine and disassembling (splitting)
the crankcase.

ENGINE REMOVAL AND DISASSEMBLY

TOOL NAME

PART NUMBER

ENGINE SUPPORT CRADLE

HD-42310-45

Remove engine from chassis. See

3.10 REMOVING

ENGINE FROM CHASSIS

Support engine using ENGINE SUPPORT CRADLE (Part
No. HD-42310-45).

Disassemble top end. See

3.13 TOP END OVERHAUL:

DISASSEMBLY

Remove primary cover, clutch assembly, primary chain
and engine sprocket. See

5.4 PRIMARY DRIVE AND

CLUTCH: XL MODELS

5.5 PRIMARY DRIVE AND

CLUTCH: XR 1200X

Disassemble gearcase. See

3.17 BOTTOM END OVER-

HAUL: DISASSEMBLY

Remove transmission sprocket.

See

Figure 5-45

. Place transmission in 1st gear. Remove

countershaft retaining screw (1).

Place transmission in neutral. See

Figure 5-46

. Unplug

neutral switch connector [131] (2) by pulling connector
straight off neutral switch (1). Remove neutral switch and
flat washer.

See

Figure 5-47

. Verify shifter drum detent is visible in

neutral switch hole indicating that transmission is in
neutral.

sm03354

1. Countershaft retaining screw
2. Shifter shaft assembly

Figure 5-45. Countershaft Retaining Screw

sm03355

1. Neutral indicator switch
2. Neutral switch connector

Figure 5-46. Neutral Switch and Connector

sm03356

Figure 5-47. Shifter Drum Neutral Detent

10. See

Figure 5-48

and

Figure 5-49

. Compress the ratchet

arms (item 2,

Figure 5-48

) in order to clear the shifter

drum, and remove shifter shaft assembly from left crank-
case half.

11. Remove starter. See

6.10 STARTER

12. See

Figure 5-50

. With transmission still in neutral, scribe

a line on the end of the shifter drum at the 12 o'clock
position for later reference.

HOME

5-30 2013 Sportster Service: Drive/Transmission

sm03357a

1. Shifter shaft
2. Ratchet arms
3. Return spring

Figure 5-48. Shifter Shaft Assembly

sm01323a

Figure 5-49. Removing Shifter Shaft Assembly

sm03359

Figure 5-50. Scribed Line on Shifter Drum at 12 o'clock

sm03405a

1. Long fastener: left side
2. XR 1200X: double-headed long fastener
3. Short fastener: left side
4. Long fastener: right side

Figure 5-51. Crankcase Fasteners

NOTE

Crankcase assembly has 17 fasteners: 15 inserted from left
side and two inserted from right side. Make certain all fasteners
have been removed before attempting to separate crankcase
halves.

13. See

Figure 5-51

. Remove 15 crankcase fasteners (11 long

and four short) from left side of crankcase assembly.
Remove two fasteners from right side of crankcase
assembly.

HOME

2013 Sportster Service: Drive/Transmission 5-31

14. Tap crankcase gently with rawhide mallet to loosen and

separate the halves. See

Figure 5-52

. Remove left

crankcase assembly with transmission.

NOTE

Flywheel assembly slides off left main bearing by hand. No
tools are required for this operation.

15. See

Figure 5-53

. Remove flywheel assembly from right

crankcase half.

16. See

Figure 5-54

. Remove screw (1), gear detent assembly

(2) and detent spring (3) from inside transmission cavity
of right crankcase.

sm06548

Figure 5-52. Separating Crankcase Halves

sm06549

Figure 5-53. Removing Flywheel Assembly From Right

Crankcase Half

sm06783

1. Screw
2. Gear detent assembly
3. Detent spring

Figure 5-54. Gear Detent Assembly

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5-32 2013 Sportster Service: Drive/Transmission

5.9

TRANSMISSION REMOVAL AND DISASSEMBLY

TRANSMISSION REMOVAL FROM LEFT
CRANKCASE

TOOL NAME

PART NUMBER

REMOVER

B-43895-1

TRANSMISSION REMOVAL AND
INSTALLATION TOOL

B-43985

NOTE

See

Figure 5-55

. Shifter design allows for one common part

number for both countershaft shifter forks (4, 5). As the trans-
mission runs, each shifter fork develops a certain wear pattern
with its mating parts. Install shifter forks in original locations.

sm06844

1. Shifter drum
2. Mainshaft shifter fork (4th/5th)
3. Shifter fork shaft
4. Countershaft shifter fork (1st)
5. Coutnershaft shifter fork (2nd/3rd)

Figure 5-55. Shifter Forks, Drum and Shafts

See

Figure 5-56

. Remove shifter fork shafts by inserting

a small flat punch in the slots and tapping on the end of
each shaft until it falls free.

NOTE

Carefully tap on alternate sides of the shaft using the provided
slots.

See

Figure 5-57

. Remove shifter drum (1) and shifter forks

(2). Mark each shifter fork as it is removed, so it can be
reinstalled in the same location.

sm03369b

Figure 5-56. Slots For Removing Shifter Fork Shafts

sm03370a

1. Shifter drum
2. Shifter fork (3)
3. Mainshaft
4. Mainshaft 2nd gear
5. Countershaft

Figure 5-57. Transmission Assembly

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2013 Sportster Service: Drive/Transmission 5-33

sm03372

1. Press ram
2. Transmission remover
3. Crankcase
4. Transmission assembly (countershaft visible)
5. Parallel support (2)
6. Press bed

Figure 5-58. Pressing Transmission From Left Crankcase

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

Use the TRANSMISSION REMOVAL AND INSTALLATION
TOOL (Part No. B-43985) to remove the transmission.

See

Figure 5-58

. Remove left crankcase half and transmis-

sion assembly (4) from engine stand.

Place crankcase half (3) and transmission assembly
(4) on arbor press (1) and support transmission
assembly on parallel supports (5).

Press transmission assembly using REMOVER (Part
No. B-43895-1) (2) to remove transmission from
crankcase half.

Remove crankcase from press.

MAINSHAFT/COUNTERSHAFT

NOTES

•

Transmission operation creates a specific wear pattern
on the parts. Always install parts in their original locations
and orientations.

•

See

Figure 5-59

. As each component is removed, place

it on a clean surface in the exact order of removal.

sm03373a

1. Mainshaft
2. Countershaft

Figure 5-59. Transmission Parts Identification

MAINSHAFT DISASSEMBLY

TOOL NAME

PART NUMBER

TRANSMISSION SHAFT RETAINING
RING PLIERS

J-5586-A

NOTES

•

Mainshaft 2nd and 3rd gears are integral to the shaft.

•

Mainshaft 1st gear is directional. Mark gear when removed
for correct installation.

•

Press transmission assembly out of left crankcase half to
service mainshaft and countershaft.

•

All thrust washers are one common part number. This
transmission requires no shimming.

•

Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.

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 5-60

. Remove 1st gear (1).

Use TRANSMISSION SHAFT RETAINING RING PLIERS
(Part No. J-5586-A) to expand and remove retaining ring
(2). Discard retaining ring.

Slide thrust washer (3) off end of mainshaft.

Remove 4th gear (4) and split bearing (5). Discard bearing.

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5-34 2013 Sportster Service: Drive/Transmission

sm03375

Split bearing

Mainshaft 1st gear

Retaining ring

Mainshaft

Mainshaft 3rd gear (integral to shaft)

Thrust washer

Mainshaft 4th gear

Mainshaft 2nd gear (integral to shaft)

Figure 5-60. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly

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 dry with com-
pressed air.

Check gear teeth for damage. Replace if necessary.

Inspect the engaging dogs on the gears. Replace if
necessary.

COUNTERSHAFT DISASSEMBLY

TOOL NAME

PART NUMBER

RETAINING RING PLIERS

J-5586-A

NOTES

•

Countershaft 5th gear is integral to the shaft.

•

Once the transmission assembly has been pressed out
of the left crankcase half, the mainshaft and countershaft
assemblies can be serviced separately.

•

All thrust washers are one common part number. This
transmission requires no shimming.

•

Use correct retaining ring pliers with correct tips. Verify
that tips are not excessively worn or damaged.

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 5-61

. Remove spacer (19) and 2nd gear (18)

from the end of the of the countershaft (2). Remove and
discard split bearing (17).

Remove spacer (16).

NOTE

When removing the dog ring (15), it is important to mark the
direction of the ring on the shaft as parts establish wear pat-
terns.

Remove dog ring (15).

Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and remove retaining ring (14). Discard retaining
ring.

Remove thrust washer (13), 3rd gear (12), and split
bearing (11). Discard bearing.

Remove thrust washer (10).

Expand, remove and discard retaining ring (9).

Remove 4th gear (8) and dog ring (7).

Expand, remove and discard retaining ring (6).

10. Remove thrust washer (5), 1st gear (4) and split bearing

(3). Discard bearing.

HOME

2013 Sportster Service: Drive/Transmission 5-35

Cleaning and Inspection

Clean all parts (except bearings) in cleaning solvent and
blow dry with compressed air.

Check gear teeth for damage. Replace if necessary.

Inspect the engaging dogs on the gears. Replace if
necessary.

13 14

sm03376

15.

Dog ring

Countershaft 4th gear

Countershaft 5th gear
(integral to shaft)

16.

Spacer

Retaining ring

10.

Countershaft

17.

Thrust washer

Split bearing

18.

11.

Countershaft 2nd gear

Split bearing

19.

12.

Countershaft 1st gear

Spacer

Countershaft 3rd gear

13.

Thrust washer

14.

Retaining ring

7. Dog ring

Figure 5-61. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly

HOME

5-36 2013 Sportster Service: Drive/Transmission

5.10

TRANSMISSION ASSEMBLY

MAINSHAFT ASSEMBLY

TOOL NAME

PART NUMBER

RETAINING RING PLIERS

J-5586-A

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

•

Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.

•

Lubricate spit bearings and internal bores of gears with
SCREAMIN' EAGLE ASSEMBLY LUBE prior to assembly.

See

Figure 5-62

. Install

new

split bearing (5) in 4th gear

position on mainshaft.

Install 4th gear (4) and thrust washer (3).

Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install new retaining ring (2).

Install 1st gear (1).

sm03375

Split bearing

Mainshaft 1st gear

Retaining ring

Mainshaft

Mainshaft 3rd gear (integral to shaft)

Thrust washer

Mainshaft 4th gear

Mainshaft 2nd gear (integral to shaft)

Figure 5-62. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly

COUNTERSHAFT ASSEMBLY

TOOL NAME

PART NUMBER

RETAINING RING PLIERS

J-5586-A

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

•

Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.

•

During assembly, the split bearings and the internal bores
of the gears must be lubricated with SCREAMIN' EAGLE

ASSEMBLY LUBE prior to assembly. Leaving these parts
dry could accelerate wear at start-up.

See

Figure 5-63

. Install

new

split bearing (3) in 1st gear

position on mainshaft.

Install 1st gear (4) and thrust washer (5).

Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install

new

retaining ring (6).

Install dog ring (7) onto 4th gear (8). Now install dog ring
and gear assembly onto countershaft.

Expand and install

new

retaining ring (9).

Install thrust washer (10).

Install

new

split bearing (11) in 3rd gear position on

mainshaft.

Install 3rd gear (12) and thrust washer (13).

HOME

2013 Sportster Service: Drive/Transmission 5-37

Content .. 38 39 40 41 ..