Content .. 39 40 41 42 ..

Harley Davidson 2013 Sportster Models. Service Manual - page 41

Expand and install

new

retaining ring (14).

10. Install dog ring (15). Make sure to install with dog ring

facing same direction as when it was removed.

11. Install spacer (16).

12. Install

new

split bearing (17) in 2nd gear position on shaft.

13. Install 2nd gear (18) and spacer (19).

NOTE

At this point both mainshaft and countershaft sub-assemblies
are ready to be pressed into the left crankcase half.

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 5-63. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly

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5-38 2013 Sportster Service: Drive/Transmission

5.11

MAIN DRIVE GEAR AND BEARING

GENERAL

NOTE

See

Figure 5-64

. Main drive gear (2) removal requires

replacement of the main drive gear bearing (7 or 14). Gear
removal procedure destroys bearing's inner race.

sm01328

Countershaft bearing (closed end)

Needle bearing (2)

Main drive gear

Retaining ring

10.

Oil seal

O-ring

11.

Oil seal

Retaining ring

12.

Spacer (XR 1200X)

Shifter drum bushing

13.

Right crankcase

O-ring (XR 1200X)

14.

Double roller bearing (XR 1200X)

Ball bearing (XL models)

Figure 5-64. Main Drive Gear and Bearing Assembly

HOME

2013 Sportster Service: Drive/Transmission 5-39

REMOVAL

TOOL NAME

PART NUMBER

CROSS PLATE

B-45847

RECEIVER CUP

HD-35316-11

BEARING DRIVER

HD-35316-13

8 INCH BOLT

HD-35316-4A

WASHER

HD-35316-7

BEARING DRIVER

HD-35316-9

MAIN DRIVE GEAR REMOVER AND
INSTALLER SET

HD-35316-D

Main Drive Gear

Split crankcases. See

5.8 CASE DISASSEMBLY FOR

TRANSMISSION REMOVAL

See

Figure 5-65

. From inside right crankcase, tap out seal

(3) at end of main drive gear (1). Discard seal.

Obtain MAIN DRIVE GEAR REMOVER AND INSTALLER
SET (Part No. HD-35316-D). See

Figure 5-66

. Position

CROSS PLATE (Part No. B-45847) (1) on right crankcase
as shown. Position so roll pins (2) fit into crankcase mating
screw holes and bolt hole (3) is centered over main drive
gear (4).

sm01360

1. Main drive gear
2. Needle bearing (2)
3. Seal
4. O-ring
5. Retaining ring

Figure 5-65. Main Drive Gear Assembly (typical)

See

Figure 5-67

. Insert 8 INCH BOLT (Part No. HD-35316-

4A) (2) through cross plate (1) and main drive gear (3).

At outside of case, place WASHER (Part No. HD-35316-
7) (4), BEARING (5), FLAT WASHER (6) and NUT (7)
over end of bolt. Tighten nut until main drive gear is free.

sm01303

1. Cross plate
2. Roll pin (2)
3. Bolt hole
4. Main drive gear

Figure 5-66. Positioning Cross Plate (typical)

sm01304

1. Cross plate
2. 8 in bolt
3. Main drive gear
4. Washer
5. Bearing
6. Washer
7. Nut

Figure 5-67. Removing Main Drive Gear (typical)

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5-40 2013 Sportster Service: Drive/Transmission

Main Drive Gear Ball Bearing

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

See

Figure 5-64

. Remove and discard oil seal (10).

Remove and discard main drive gear bearing retaining
ring (9).

XR 1200X:

Remove spacer (12) and O-ring (13).

See

Figure 5-68

. Install driver components: From inside

crankcase, position bearing driver (2) over main drive gear
bearing.

XL Models:

Use the BEARING DRIVER (Part

No. HD-35316-9).

XR 1200X:

Use the BEARING DRIVER (Part No. HD-

35316-13).

Insert 8 INCH BOLT (Part No. HD-35316-4A) (1) through
bearing driver and bearing.

At outside of case, slide RECEIVER CUP (Part No. HD-
35316-11) (3) onto bolt and over bearing. Install the
bearing (4), flat washer (5) and nut (6) over end of bolt.

NOTE

Support bearing remover assembly as you remove bearing in
the following step. Entire assembly will fall out of crankcase
when bearing comes free.

Tighten nut until main drive gear ball bearing is free.

Discard main drive gear ball bearing.

sm01305a

1. 8 inch bolt
2. Bearing driver
3. Receiver cup
4. Bearing
5. Flat washer
6. Nut

Figure 5-68. Removing Main Drive Gear Bearing (typical)

DISASSEMBLY

TOOL NAME

PART NUMBER

BEARING RACE PULLER

HD-95637-46B

See

Figure 5-64

. Remove retaining ring (11) from inboard

end of main drive gear (2). Discard retaining ring.

See

Figure 5-65

. Drive out needle bearings (2) from inside

bore of main drive gear (1). Discard needle bearings. Do
not reuse bearings after removal from drive gear bore.

Remove and discard O-ring (4).

NOTE

When the main drive gear is removed, a portion of the bearing
inner race remains attached to the main drive gear. Remove
this inner race before installing main drive gear.

HOME

2013 Sportster Service: Drive/Transmission 5-41

See

Figure 5-69

. Attach BEARING RACE PULLER (Part

No. HD-95637-46B) (3) to inner race (2) on main drive
gear (1).

Place main drive gear with bearing race puller assembly
onto press bed as shown in the photo.

NOTE

Provide a soft surface to catch the main drive gear when it falls
free in the next step.

Press main drive gear out of inner bearing race. Discard
inner bearing race.

sm01306

1. Main drive gear
2. Inner bearing race (not visible in this photo)
3. Bearing race puller
4. Press ram

Figure 5-69. Removing Inner Bearing Race From Main Drive

Gear (typical)

ASSEMBLY

TOOL NAME

PART NUMBER

INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION
TOOL: XL MODELS

HD-47855

INNER/OUTER MAIN DRIVE GEAR
NEEDLE BEARING INSTALLATION
TOOL: XR 1200X

HD-48643

NOTE

The correct installed bearing depth is reached when the
installation tool bottoms on the gear.

See

Figure 5-70

Figure 5-71

. Place main drive gear (4)

on press bed with gear end facing up.

Place needle bearing (3) squarely into end of drive gear
with lettered side of bearing facing up. Always press on

lettered side of bearing to install. Insert the installation tool
(2) with end stamped "INNER" facing needle bearing.

XL Models:

INNER/OUTER MAIN DRIVE GEAR

NEEDLE BEARING INSTALLATION TOOL: XL
MODELS (Part No. HD-47855)

XR 1200X:

INNER/OUTER MAIN DRIVE GEAR

NEEDLE BEARING INSTALLATION TOOL: XR
1200X (Part No. HD-48643)

Press in the inner bearing until the installation tool bottoms
on the main drive gear.

sm01307

1. Press ram
2. Needle bearing installation tool
3. Needle bearing
4. Main drive gear

Figure 5-70. Pressing Inner Needle Bearing Assembly into

Main Drive Gear: XL Models

sm05493

1. Press ram
2. Needle bearing installation tool
3. Needle bearing (not visible)
4. Main drive gear

Figure 5-71. Pressing Inner Needle Bearing Assembly into

Main Drive Gear: XR 1200X

See

Figure 5-72

Figure 5-73

. Place main drive gear (4)

on press bed with gear end facing down.

Place needle bearing (3) squarely into end of drive gear
with lettered side of bearing facing up. Always press on

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5-42 2013 Sportster Service: Drive/Transmission

lettered side of bearing to install. Insert installation tool (2)
with end stamped "OUTER" facing needle bearing.

Press in the outer needle bearing until the installation tool
bottoms on the main drive gear.

See

Figure 5-64

. Install

new

retaining ring (11) in inboard

end of main drive gear (2).

sm01308

1. Press ram
2. Needle bearing installation tool
3. Needle bearing
4. Main drive gear

Figure 5-72. Pressing Outer Needle Bearing Assembly into

Main Drive Gear: XL Models

sm05494

1. Press ram
2. Needle bearing installation tool
3. Needle bearing (not visible)
4. Main drive gear

Figure 5-73. Pressing Outer Needle Bearing Assembly into

Main Drive Gear: XR 1200X

INSTALLATION

TOOL NAME

PART NUMBER

CROSS PLATE

B-45847

INSTALLER CUP

HD-35316-12

BEARING DRIVER

HD-35316-13

8 INCH BOLT

HD-35316-4A

WASHER

HD-35316-7

BEARING DRIVER

HD-35316-8

MAIN DRIVE GEAR REMOVER AND
INSTALLER SET

HD-35316-C

MAIN DRIVE GEAR SEAL INSTALLER
KIT

HD-47856

INSTALLER

HD-47856-1

PILOT

HD-47856-2

ADAPTER

HD-47856-4

LARGE NUT

HD-47856-5

Main Drive Gear Bearing: XL Models

See

Figure 5-74

. Place CROSS PLATE (Part No. B-45847)

(1) on right crankcase as shown. Position cross plate so
that roll pins (2) fit into crankcase mating screw holes and
bolt hole (3) in cross plate is centered over crankcase
bearing bore (4).

See

Figure 5-75

. Insert 8 INCH BOLT (Part No. HD-35316-

4A) (2) through cross plate (1) and main drive gear bearing
bore.

Place main drive gear bearing (3), BEARING DRIVER
(Part No. HD-35316-8) (4), BEARING (5), FLAT WASHER
(6) and NUT (7) over end of bolt.

NOTE

Do not continue to tighten nut after bearing bottoms against
lip in crankcase bearing bore. Tightening nut too much can
break lip in bearing bore casting.

Tighten nut until main drive gear bearing bottoms against
lip cast into crankcase bearing bore.

Remove main drive gear bearing installer tool.

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

See

Figure 5-78

. At outside of case install

new

beveled

retaining ring (9) in groove inside bearing bore with
beveled side facing outside of case.

Lubricate main drive gear bearing with SCREAMIN'
EAGLE ASSEMBLY LUBE.

HOME

2013 Sportster Service: Drive/Transmission 5-43

sm01309

1. Cross plate
2. Roll pin (2)
3. Bolt hole
4. Crankcase bearing bore

Figure 5-74. Positioning Cross Plate: XL Models

sm01310a

1. Cross plate
2. 8 inch bolt
3. Main drive gear bearing
4. Bearing driver
5. Bearing
6. Flat washer
7. Nut

Figure 5-75. Installing Main Drive Gear Bearing: XL Models

Main Drive Gear Bearing: XR 1200X

NOTE

Due to the design of the bearing, BEARING DRIVER (Part
No. HD-35316-13) and an arbor press must be used to press
the main drive gear bearing on all XR 1200X.

See

Figure 5-76

. From the outside of the case, position

the main drive gear bearing (3) and bearing driver (2) over
bearing bore in crankcase.

Press on main drive gear bearing driver until driver bottoms
against lip cast into crankcase bearing bore.

sm05744

1. Press ram
2. Bearing driver
3. Main drive gear bearing

Figure 5-76. Installing Main Drive Gear Bearing: XR 1200X

Main Drive Gear

See

Figure 5-77

. Lubricate both main drive gear needle

bearing assemblies with SPECIAL PURPOSE GREASE.

See

Figure 5-78

. Install

new

O-ring (3) into groove in main

drive gear (2). Lubricate O-ring with SCREAMIN' EAGLE
ASSEMBLY LUBE.

sm03400

Figure 5-77. Lubricating Main Drive Gear Needle Bearing

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5-44 2013 Sportster Service: Drive/Transmission

sm01328

Countershaft bearing (closed end)

Needle bearing (2)

Main drive gear

Retaining ring

10.

Oil seal

O-ring

11.

Oil seal

Retaining ring

12.

Spacer (XR 1200X)

Shifter drum bushing

13.

Right crankcase

O-ring (XR 1200X)

14.

Double roller bearing (XR 1200X)

Ball bearing (XL models)

Figure 5-78. Main Drive Gear and Bearing Assembly

See

Figure 5-79

. Insert 8 INCH BOLT (Part No. HD-35316-

4A) (1) through WASHER (Part No. HD-35316-7) (2) and
main drive gear (3). From inside of case insert bolt with
washer and main drive gear through inner race of main
drive gear bearing.

At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (4), BEARING (5), FLAT WASHER (6) and NUT
(7) over end of bolt. Tighten nut until main drive gear bot-
toms against main drive gear bearing.

Remove

MAIN

DRIVE

GEAR

REMOVER

AND

INSTALLER SET (Part No. HD-35316-C) set.

See

Figure 5-78

. Tap in

new

oil seal (4) at threaded end

of main drive gear to a depth of 0.060-0.030 in (1.524-
0.762 mm).

HOME

2013 Sportster Service: Drive/Transmission 5-45

sm01311b

1. 8 inch bolt
2. Washer
3. Main drive gear
4. Installer cup
5. Bearing
6. Flat washer
7. Nut

Figure 5-79. Installing Main Drive Gear (typical)

Main Drive Gear Seal

XR 1200X:

See

Figure 5-78

. Install spacer (12) and

new

O-ring (13) onto main drive gear.

Obtain MAIN DRIVE GEAR SEAL INSTALLER KIT (Part
No. HD-47856).

See

Figure 5-80

. From outside of crankcase, install PILOT

(Part No. HD-47856-2) over end of main drive gear bearing
inner race.

Coat lips of

new

main drive gear seal with SCREAMIN'

EAGLE ASSEMBLY LUBE.

See

Figure 5-81

. Place seal over pilot and position seal

squarely in end of crankcase bore.

NOTE

ADAPTER (Part No. HD-47856-4) and main drive gear have
left-hand threads.

See

Figure 5-82

. Thread ADAPTER (Part No. HD-47856-

4) onto end of main drive gear several turns. Do NOT
tighten on drive gear. Doing so could make it difficult to
remove adapter after seal has been installed.

sm01312a

Figure 5-80. Install Pilot (typical)

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5-46 2013 Sportster Service: Drive/Transmission

sm01313a

Figure 5-81. Install Main Drive Gear Seal (typical, XL model

shown)

sm01314a

Figure 5-82. Install Adapter (typical, XL model shown)

See

Figure 5-83

. Slide INSTALLER (Part No. HD-47856-

1) over adapter until cupped end of installer is flat against
seal.

See

Figure 5-84

. Thread LARGE NUT (Part No. HD-

47856-5) onto end of adapter, until it tightens against
installer.

See

Figure 5-85

. Place crow's foot wrench (1) with 1/2

inch drive breaker bar (2) on large nut. Place an adjustable
wrench (3) on flats of hex head cast into end of adapter.

10. Holding adjustable wrench, tighten large nut with crow's

foot wrench until outer face of seal is flush with outer edge
of crankcase bore.

NOTE

It is acceptable to recess seal to about 0.030 in (0.762 mm)
below outer edge of bore. Seal will be controlled by tool.

11. Remove nut, installer, adapter and pilot.

sm01315a

Figure 5-83. Place Installer over Adapter (typical, XL model

shown)

HOME

2013 Sportster Service: Drive/Transmission 5-47

sm01316a

Figure 5-84. Install Nut (typical, XL model shown)

sm01317a

1. Crowfoot wrench
2. 1/2 inch breaker bar
3. Adjustable wrench

Figure 5-85. Press Seal Into Crankcase (typical, XL model

shown)

HOME

5-48 2013 Sportster Service: Drive/Transmission

5.12

TRANSMISSION RIGHT CASE BEARINGS

REMOVAL

TOOL NAME

PART NUMBER

BUSHING AND BEARING PULLER

HD-95760-69A

1/2 INCH COLLET

HD-95765-69A

Split crankcases. See

5.8 CASE DISASSEMBLY FOR

TRANSMISSION REMOVAL

Countershaft Needle Bearing

See

Figure 5-86

. From inside transmission case use a bearing

driver to remove countershaft bearing (1) from crankcase bore.

Shifter Drum Bushing

See

Figure 5-86

. The shifter drum bushing (2) is a press

fit in the right crankcase half. Inspect the bushing against
the corresponding end of the shifter drum for proper fit
and wear.

If bushing is to be replaced, use BUSHING AND BEARING
PULLER (Part No. HD-95760-69A) with 1/2 INCH COLLET
(Part No. HD-95765-69A) to remove bushing from crank-
case bore.

INSTALLATION

TOOL NAME

PART NUMBER

SNAP-ON BUSHING DRIVER SET

A-157C

Countershaft Needle Bearing

Find a bearing driver 1-1/4 inch in diameter.

See

Figure 5-86

. Position the open end of the countershaft

bearing (1) toward the bore in the outside of the case.

Square the driver against the closed end of the bearing.

Drive the bearing flush or no more than 0.030 in (0.762
mm) below the outside surface.

Lubricate with SCREAMIN' EAGLE ASSEMBLY LUBE.

Shifter Drum Bushing

See

Figure 5-86

. Using SNAP-ON BUSHING DRIVER

SET (Part No. A-157C) and the 1/2 inch adapter (Part No.
A157-8), install a

new

shifter drum bushing (2).

Lubricate with SCREAMIN' EAGLE ASSEMBLY LUBE.

sm07172

1. Countershaft needle bearing
2. Shifter drum bushing

Figure 5-86. Transmission Right Case Bearings

HOME

2013 Sportster Service: Drive/Transmission 5-49

5.13

TRANSMISSION LEFT CASE BEARINGS

REMOVAL

TOOL NAME

PART NUMBER

SNAP-ON SNAP RING PLIERS

PR-36

Mainshaft and Countershaft Bearings

Split crankcases. See

5.8 CASE DISASSEMBLY FOR

TRANSMISSION REMOVAL

Disassemble transmission. See

5.9 TRANSMISSION

REMOVAL AND DISASSEMBLY

Remove shifter forks and drum.

Remove countershaft and mainshaft.

Inspect the mainshaft and countershaft ball bearings for
pitting, scoring, discoloration or other damage.

See

Figure 5-88

. If bearing replacement is required,

remove retaining rings (1, 2) using SNAP-ON SNAP RING
PLIERS (Part No. PR-36).

Press out bearings (3, 4) from the inside of the crankcase.

Shifter Drum Bushing

Inspect the shifter drum bushing for pitting, scoring, discol-
oration or excessive wear.

If bushing requires replacement, press bushing out of
crankcase from primary side toward inside of case.

INSTALLATION

Mainshaft and Countershaft Bearings

Place crankcase on press with inside surface of crankcase
downward.

Lay bearing squarely over bore with printed side of bearing
upward.

Place a driver (slightly smaller than outside diameter of
bearing) against outer race.

Press bearing into bore until bearing bottoms against
shoulder.

Install

new

retaining ring with beveled side facing away

from bearing.

Shift Drum Bushing

Place crankcase on press with outside surface of crank-
case downward.

See

Figure 5-87

. Lay bushing squarely over bore. Using

a pressing tool larger than OD of bushing, press bushing
into bore until tool contacts crankcase.

sm03388

1. Press bushing to contact shoulder in crankcase

half.

2. Shifter drum bushing.
3. Outside crankcase

Figure 5-87. Shifter Drum Bushing Assembly

sm01370

1. Retaining ring
2. Retaining ring
3. Mainshaft bearing
4. Countershaft bearing

Figure 5-88. Ball Bearing Assembly

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5-50 2013 Sportster Service: Drive/Transmission

5.14

TRANSMISSION INSTALLATION

GENERAL

Before reinstalling transmission and reassembling crankcase
halves, perform any necessary engine overhaul procedures.
See

3.9 BOTTOM END SERVICE

and

3.8 TOP END SERVICE

INSTALLATION

TOOL NAME

PART NUMBER

TRANSMISSION REMOVAL AND
INSTALLATION TOOL

B-43985

INSTALLER

B-43985-3

GUIDE

B-43985-4

CASE HOLDING FIXTURE

HD-46285-2

TORQUE VALUE

FASTENER

10.2-12.4 Nm

90-110

in-lbs

Gear detent assembly screw

See

Figure 5-89

. Assemble detent spring (3) onto gear

detent assembly (2).

Install detent assembly with spring into place in transmis-
sion cavity of right crankcase.

Secure with screw (1). Tighten to 90-110

in-lbs

(10.2-12.4

Nm).

NOTE

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

See

Figure 5-90

. Place transmission assembly (2) onto

CASE HOLDING FIXTURE (Part No. HD-46285-2) (3) on
press bed. Use support block(s) (4) if necessary.

Screw the GUIDE (Part No. B-43985-4) (1) into end of
countershaft.

sm06783

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

Figure 5-89. Gear Detent Assembly

sm01318a

1. Countershaft guide
2. Transmission
3. Transmission fixture
4. Support block(s)

Figure 5-90. Transmission on Fixture

See

Figure 5-91

. Install left crankcase (3) over transmis-

sion assembly (4).

Place the INSTALLER (Part No. B-43985-3) (2) over
mainshaft and countershaft bearings in crankcase.

Position crankcase and transmission assemblies on press
with installer under press ram (1).

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2013 Sportster Service: Drive/Transmission 5-51

sm01319a

1. Press ram
2. Installer
3. Crankcase
4. Transmission
5. Transmission fixture

Figure 5-91. Pressing Transmission into Left Crankcase

NOTE

Verify that the crankcase does not tilt when pressed onto
transmission assembly. Place press ram on the installer closer
to mainshaft to keep the crankcase level.

Press crankcase onto transmission assembly until shafts
bottom out on bearings.

10. Remove left crankcase with transmission assembly from

press.

NOTE

When removing assembly from fixture, prevent 1st gear from
falling off shaft. Gear can be damaged if it strikes a hard sur-
face.

SHIFTER FORKS AND DRUM ASSEMBLY

NOTES

•

See

Figure 5-92

. Each shifter fork develops a wear pattern

with its mating parts. Install each shifter fork in its original
location.

•

Lubricate the shaft bore in each shifter fork with
SCREAMIN' EAGLE ASSEMBLY LUBE before assembly.

Place 2nd/3rd gear shifter fork onto dog ring between
countershaft 2nd and 3rd gears.

Install shifter drum into left case half with scribed line at
12 o'clock. This will place shifter drum in neutral position.

NOTE

See

Figure 5-93

. Install shifter fork shafts in the left case half

by lightly tapping on the end of the shaft with a brass or hard
plastic hammer until shaft is seated in bore.

Place 1st gear shifter fork onto dog ring between counter-
shaft 1st and 4th gear gears. Install shifter fork shaft

through two installed shifter forks and into left crankcase
half.

Install 4th/5th gear shifter fork onto sliding gear with dogs
located on mainshaft. Install remaining shifter fork shaft
through last installed shifter fork and into left crankcase
half.

NOTE

Seat shifter fork shafts in left crankcase half bore using light
taps with a brass hammer.

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 5-92. Shifter Forks, Drum and Shafts

sm01320a

Figure 5-93. Installing Shifter Fork Shafts

HOME

5-52 2013 Sportster Service: Drive/Transmission

ASSEMBLING CRANKCASES

TOOL NAME

PART NUMBER

GEAR DETENT ASSEMBLY AID

B-45520

CRANKSHAFT GUIDE TOOL

HD-42326-A

TORQUE VALUE

FASTENER

20.3-25.8 Nm

15-19 ft-lbs

Crankcase fastener

13.6-20.3 Nm

120-180

in-lbs

Neutral indicator switch

See

Figure 5-94

. Retract detent assembly in right case

half and thread GEAR DETENT ASSEMBLY AID (Part
No. B-45520) into neutral switch hole until it has bottomed
in right case half.

See

Figure 5-95

. Install flywheel assembly into right

crankcase half.

Do not rotate right crankcase half in engine stand such
that flywheel sprocket shaft is facing down. The flywheel
assembly can fall out, resulting in parts damage or mod-
erate injury. (00553b)

NOTE

Always place transmission in 1st gear when assembling
crankcases. Other gear selections could cause damage.

Place transmission in 1st gear.

See

Figure 5-96

. Assemble crankcase halves together.

Slide CRANKSHAFT GUIDE TOOL (Part No. HD-
42326-A) onto flywheel sprocket shaft.

Apply a thin coat of HARLEY-DAVIDSON GRAY
HIGH-PERFORMANCE SEALANT - GRAY to crank-
case joint faces.

Lubricate main drive gear inner bearings with
SCREAMIN' EAGLE ASSEMBLY LUBE.

Carefully fit crankcases together.

Apply several drops of LOCTITE 262 HIGH
STRENGTH THREADLOCKER AND SEALANT (red)
to last few threads of crankcase fasteners.

Install 11 long and four short from the left side and
two long from the right side.

See

Figure 5-97

. In sequence, tighten to 15-19 ft-lbs

(20.3-25.8 Nm).

Remove GEAR DETENT ASSEMBLY AID and install
neutral indicator switch and flat washer. Tighten to 120-
180

in-lbs

(13.6-20.3 Nm).

sm01372

1. Detent assembly
2. Detent assembly aid

Figure 5-94. Using Gear Detent Assembly Aid (Part No.

B-45520)

sm06549

Figure 5-95. Installing Flywheel Assembly In Right

Crankcase

HOME

2013 Sportster Service: Drive/Transmission 5-53

Content .. 39 40 41 42 ..