Harley Davidson Sportster Models 2009. Service Repair Manual

5.9

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

3.12 REMOVING

ENGINE FROM CHASSIS

Support engine using ENGINE SUPPORT CRADLE (Part
No. HD-42310-45) and the appropriate engine stand.

Disassemble top end. See

3.15 TOP END OVERHAUL:

DISASSEMBLY

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

5.5 PRIMARY DRIVE AND

CLUTCH: XL MODELS

5.6 PRIMARY DRIVE AND

CLUTCH: XR MODELS

Disassemble gearcase. See

3.17 BOTTOM END OVER-

HAUL: DISASSEMBLY

Remove transmission sprocket.

See

Figure 5-49

. Place transmission in 1st gear. Remove

countershaft retaining screw (1).

Place transmission in neutral. See

Figure 5-50

. Unplug

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

See

Figure 5-51

. Verify shifter drum detent is visible in

neutral switch hole indicating that transmission is in
neutral.

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Countershaft retaining screw

Shifter shaft assembly

Figure 5-49. Countershaft Retaining Screw

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Neutral indicator switch

Neutral switch connector

Figure 5-50. Neutral Switch and Connector

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Figure 5-51. Shifter Drum Neutral Detent

10. See

Figure 5-52

and

Figure 5-53

. Depress ratchet arms

(item 2,

Figure 5-52

) in order to clear the shifter drum, and

remove shifter shaft assembly from left crankcase half.

11. Remove starter. See

6.13 STARTER

12. See

Figure 5-54

. With transmission still in neutral, scribe

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

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2009 Sportster Service: Drive/Transmission 5-37

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Short fastener

Left side

Right side

XR Models: double-headed bolt

Indicates crankcase fastener locations

Figure 5-55. 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 5-55

. Remove 15 crankcase fasteners (11 long

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

14. Tap crankcase gently with rawhide mallet to loosen and

separate the halves. See

Figure 5-56

. 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 5-57

. Remove flywheel assembly from right

crankcase half.

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Figure 5-56. Separating Crankcase Halves

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2009 Sportster Service: Drive/Transmission 5-39

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Figure 5-57. Removing Flywheel Assembly From Right

Crankcase Half (typical, XL model shown)

16. See

Figure 5-58

. Remove screw (1), gear detent assembly

(2) and detent spring (3) from inside transmission cavity
of right crankcase (4).

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Screw

Gear detent assembly

Detent spring

Right crankcase

Figure 5-58. Gear Detent Assembly

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5-40 2009 Sportster Service: Drive/Transmission

5.10

TRANSMISSION REMOVAL AND DISASSEMBLY

TRANSMISSION REMOVAL FROM LEFT
CRANKCASE

TOOL NAME

PART NUMBER

TRANSMISSION REMOVER

B-43895-1

NOTE

See

Figure 5-59

. Shifter design allows for one common part

number for both countershaft shifter forks. As the transmission
runs, each shifter fork develops a certain wear pattern with its
mating parts. For this reason, it is important that each shifter
fork be reinstalled in its original location.

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Mainshaft

Mainshaft shifter fork (4/5)

Drum (left side)

Drum (right side)

Countershaft

Countershaft shifter fork (2/3)

Countershaft shifter fork (1)

Figure 5-59. Shifter Forks, Drum and Shafts

See

Figure 5-60

. 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 5-61

. 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.

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Figure 5-60. Slots For Removing Shifter Fork Shafts

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Shifter drum

Shifter fork (3)

Mainshaft

Mainshaft 2nd gear

Countershaft

Figure 5-61. Transmission Assembly

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2009 Sportster Service: Drive/Transmission 5-41

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12.

Bushing

Detent spring

13.

Detent spring sleeve assembly

Shifter stop pin

14.

Shifter return spring

Screw

15.

Shifter fork shaft (2)

Extension spring

16.

Shifter lever assembly

Shifter fork (4th/5th)

17.

Right hand crankcase bushing

Rubber washer

18.

Screw

Shifter cam assembly

19.

Shifter fork (1st)

Washer

20.

Foot shift lever

Shifter fork (2nd/3rd)

10.

21.

Retaining ring

Shifter peg

22.

11.

Oil seal

Bearing

Figure 5-62. Shifter Mechanism

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5-42 2009 Sportster Service: Drive/Transmission

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Press ram

Transmission remover

Crankcase

Transmission assembly (countershaft visible)

Parallel support (2)

Press bed

Figure 5-63. 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)

See

Figure 5-63

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

Remove crankcase from press.

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2009 Sportster Service: Drive/Transmission 5-43

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25.

13.

Dog ring

Mainshaft

Oil seal

26.

14.

Retaining ring

Thrust washer

Mainshaft 3rd gear (integral to
shaft)

27.

Ball bearing (XL models)

Countershaft 2nd gear

15.

28.

Mainshaft 2nd gear (integral to
shaft)

Spacer

O-ring

29.

Oil seal

Countershaft bearing

16.

30.

Mainshaft bearing

Retaining ring

Needle bearing (2)

31.

17.

Mainshaft 5th gear

Countershaft retaining screw

Retaining ring

18.

32.

Closed end bearing

Mainshaft 1st gear

Retaining ring

33.

19.

Spacer (XR models)

Countershaft 5th gear (integral
to shaft)

Retaining ring (4)

10.

34.

Thrust washer (4)

O-ring (XR models)

20.

35.

Countershaft

11.

Double roller bearing (XR
models)

Mainshaft 4th gear

12.

21.

Split bearing (4)

Countershaft 1st gear

22. Dog ring
23. Countershaft 4th gear
24. Countershaft 3rd gear

Figure 5-64. Transmission Assembly

MAINSHAFT/COUNTERSHAFT

NOTES

•

As the transmission runs, each part develops a certain
wear pattern and a kind of "set" with its mating parts. For
this reason, it is important that each component be rein-
stalled in its original location and facing its original direc-
tion.

•

See

Figure 5-65

. As each component is removed, place

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

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5-44 2009 Sportster Service: Drive/Transmission

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Mainshaft

Countershaft

Figure 5-65. 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.

•

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.

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 5-66

. 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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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 5-66. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly

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2009 Sportster Service: Drive/Transmission 5-45

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 and blow dry with
compressed air.

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

Inspect the engaging dogs on the gears. Replace the gears
if dogs are rounded, cracked, battered, chipped or dimpled.

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 5-67

. 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.

Cleaning and Inspection

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

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

Inspect the engaging dogs on the gears. Replace the gears
if dogs are rounded, cracked, battered, chipped or dimpled.

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5-46 2009 Sportster Service: Drive/Transmission

13 14

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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

Dog ring

Figure 5-67. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly

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2009 Sportster Service: Drive/Transmission 5-47

5.11

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.

•

During assembly, the split bearings and the internal bores
of the gears must be lubricated with Harley-Davidson
FORMULA+ TRANSMISSION AND PRIMARY CHAIN-
CASE LUBRICANT prior to assembly. Leaving these parts
dry could accelerate wear at start-up.

See

Figure 5-68

. 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).

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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 5-68. 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.

•

See

Figure 5-69

. Install new split bearing (3) in 1st gear

position on mainshaft.

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

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5-48 2009 Sportster Service: Drive/Transmission

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).

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

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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

Dog ring

Figure 5-69. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly

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2009 Sportster Service: Drive/Transmission 5-49

5.12

MAIN DRIVE GEAR AND BEARING

GENERAL

NOTE

See

Figure 5-70

. When removing the main drive gear (2), the

gear is pressed out against the resistance of the ball bearing

(7 or 14) inner race. Without any support at the inner race, the
bearing is destroyed. Whenever the main drive gear is removed
the main drive gear bearing must also be replaced.

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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 models)

Shifter drum bushing

13.

Right crankcase

O-ring (XR models)

14.

Double roller bearing (XR models)

Ball bearing (XL models)

Figure 5-70. Main Drive Gear and Bearing Assembly

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5-50 2009 Sportster Service: Drive/Transmission

REMOVAL

TOOL NAME

PART NUMBER

CROSS PLATE

B-45847

RECEIVER CUP

HD-35316-11

BEARING DRIVER

HD-35316-13

8 IN. 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

5.9 CASE DISASSEMBLY FOR

TRANSMISSION REMOVAL

See

Figure 5-71

. 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 5-72

. Position

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 main drive gear (4).

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Main drive gear

Needle bearing (2)

Seal

O-ring

Retaining ring

Figure 5-71. Main Drive Gear Assembly (typical)

See

Figure 5-73

. Insert 8 IN. 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), NICE BEARING (5), FLAT WASHER (6) and NUT
(7) over end of bolt. Tighten nut until main drive gear is
free.

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Cross plate

Roll pin (2)

Bolt hole

Main drive gear

Figure 5-72. Positioning Cross Plate (typical)

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Cross plate

8 in. bolt

Main drive gear

Washer

Nice bearing

Washer

Nut

Figure 5-73. Removing Main Drive Gear (typical)

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2009 Sportster Service: Drive/Transmission 5-51

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 5-70

. Remove and discard oil seal (10).

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

XR Models: remove spacer (12) and o-ring (13).

See

Figure 5-74

. Install driver components: From inside

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

XL Models:BEARING DRIVER (Part No. HD-35316-
9).

XR Models:BEARING DRIVER (Part No. HD-35316-
13).

Insert 8 IN. 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 NICE
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.

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8 in. bolt

Bearing driver

Receiver cup

Nice bearing

Flat washer

Nut

Figure 5-74. Removing Main Drive Gear Bearing (typical,

XL model shown)

DISASSEMBLY

TOOL NAME

PART NUMBER

BEARING RACE PULLER

HD-95637-46B

See

Figure 5-70

. Remove retaining ring (11) from inboard

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

See

Figure 5-71

. Drive out needle bearings (2) from inside

bore of main drive gear (1) using appropriate bearing and
bushing puller. 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. This inner
race must be removed before the main drive gear can be re-
installed.

See

Figure 5-75

. 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.

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Main drive gear

Inner bearing race (not visible in this photo)

Bearing race puller

Press ram

Figure 5-75. Removing Inner Bearing Race From Main Drive

Gear (typical)

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5-52 2009 Sportster Service: Drive/Transmission

Harley Davidson Sportster Models 2009. Service Repair Manual - page 66