Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual

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240

CHAPTER SIX

Inspection

1. Inspect each shift fork (Figure 31) for excessive

wear or damage. Replace worn or damaged shift

forks as required.

2. Measure the thickness of each shift fork finger

(A, Figure 32) where it contacts the sliding gear

groove (Figure 33). Replace any shift fork with a

finger thickness worn to the specification in Table 2.

3. Check the shift forks for arc-shaped wear or burn

marks (B, Figure 32). Replace damaged shift forks.

4. Roll the shift fork shaft on a flat surface and

check for bending. Replace the shaft if bent.

5. Install each shift fork on the shift shaft. The shift

fingers must slide smoothly with no binding or

roughness.

Assembly

Refer to Figure 34 to identify the transmission

gears.

Mainshaft

1. Coat all bearing and sliding surfaces with assem-

bly oil.

2. To install the shift forks and shaft (Figure 28),

perform the following:

a. Insert the No. 1 shift fork into the mainshaft

first gear groove.

Countershaft

b. Install the No.

shift fork into the

countershaft third gear groove.

c. Install the No. 3 shift fork into the mainshaft

second gear groove.

3. Insert the shift shaft through the transmission

case (A, Figure 29), through each of the three shift

forks and into the transmission case.

4. Install the transmission side door as described in

this chapter.

4th

1st

3rd

2nd

5th

5. Check that the shift forks move smoothly when

shifting the gears by hand.

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TRANSMISSION

241

6. Install the shifter cam as described in this chapter.

3. Remove the primary chaincase cover as de-

scribed in Chapter Five.

4. Remove the clutch release cover and clutch as-

TRANSMISSION SIDE DOOR AND

sembly as described in Chapter Five.

TRANSMISSION SHAFT ASSEMBLIES

5. Remove the primary chaincase housing as de-

scribed in Chapter Five.

The transmission side door and transmission

6. Remove the shift forks as described in this chapter.

shaft assemblies can be serviced with the transmis-

7. Remove the bearing inner race (Figure 35) from

sion installed in the frame.

the mainshaft, and perform the following:

a. Attach the mainshaft bearing race puller and

installation tool (Figure 36) against the inner

Removal

bearing race (A, Figure 37), following the

manufacturer’s instructions.

This section describes removal of the transmis-

b. Tighten the puller bolt (B, Figure 37) and

sion and side door assembly.

withdraw the inner race from the mainshaft.

1. Remove the exhaust system as described in

8. Remove the pushrod assembly (B, Figure 29).

Chapter Seven.

9. Turn the transmission by hand and shift the

2. Drain the transmission oil as described in Chap-

transmission into two different gears to lock the

ter Three.

transmission in place.

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242

CHAPTER SIX

10. If the transmission gear assemblies are going to

be removed from the side door, loosen, but do not

remove, the countershaft and mainshaft locknuts

(A, Figure 38).

Mainshaft

11. If the main drive gear is going to be removed,

remove the drive sprocket as described under Drive

Sprocket in Chapter Nine.

12. Remove the bolts securing the exhaust system

Bearing inner race

Extension shaft

mounting bracket

(B, Figure

38). Remove the

bracket.

13. Remove the bolts securing the transmission

side door (C, Figure 38) to the transmission case.

Installation

CAUTION

1. If the main drive gear was removed, install it as

When removing the transmission side

described in this chapter.

door in Step 14, do not tap against the

2. Remove all gasket residue from the side door

transmission shafts from the opposite

side. Doing so will damage the side

and transmission case mating surfaces.

door bearings.

3. Install a new gasket onto the transmission case.

If removed, install the locating pins.

4. Install the side door and transmission assembly

14. Tap against the transmission side door to

into the transmission case. Check that the side door

loosen its seal against the transmission case.

fits flush against the transmission case.

15. Install the transmission door bearing puller

5. Install the transmission side door 5/16 in. and

(Figure 39) onto the door, following the manufac-

1/4 in. bolts finger-tight. Tighten the 5/16 in. bolts

turer’s instructions. Tighten the outside screws 1/2

to the specifications in Table 3. Then do the same

turn at a time, alternating from side-to-side until

for the 1/4 in. bolts.

the door releases from the transmission case. Re-

6. Turn the transmission by hand and shift the

move the special tool.

transmission into two different gear speeds to lock

the transmission from rotation.

16. Slowly withdraw the transmission side door

and the transmission gear assemblies from the

7. To install the bearing inner race (Figure 35) onto

transmission case.

the mainshaft, perform the following:

a. The bearing inner race is

0.950-1.000 in.

17. Remove the transmission side door gasket. Do

(24.13-25.40 mm) long. When installing a

not lose the locating pins.

new race, measure it to confirm its length.

18. If necessary, service the side door and transmis-

Race length determines its final installation

sion assembly as described in this chapter.

position.

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TRANSMISSION

243

TRANSMISSION

1. Mainshaft first gear

2. Mainshaft

3. Snap ring

4. Thrust washer

5. Mainshaft third gear

6. Mainshaft second gear

7. Split bearings

8. Oil slinger assembly

9. Clutch pushrod

10. Locknut

11. Washer

12. Side door

13. Gasket

14. Spacer

15. Mainshaft fourth gear

16. Spacer

17. Countershaft fourth gear

18. Countershaft first gear

19. Countershaft

20. Countershaft third gear

21. Countershaft second

gear

22. Countershaft fifth gear

b. Use the same tool setup used for bearing inner

0.100-0.150

in.

(2.540-3.810

mm.) away

race removal.

from the main drive gear.

c. Apply clean oil to the transmission shaft bear-

h. Remove the special tools.

ing surface, shaft threads and to the inner sur-

8. Install the pushrod assembly (B, Figure 29).

face of the inner race.

9. Install the shift forks as described in this chapter.

d. Position the bearing inner race with the

10. Install the primary chaincase housing as de-

chamfered end going on first and slide it onto

scribed in Chapter Five.

the mainshaft (Figure 40).

11. Install the clutch assembly and clutch release

cover as described in Chapter Five.

e. Install the extension shaft onto the mainshaft.

12. Install the primary chaincase cover as de-

f. Place the pusher tube over the extension

scribed in Chapter Five.

shaft, along with the two flat washers and nut.

13. Install the drain plug and refill the transmission

CAUTION

oil as described in Chapter Three.

Install the inner bearing race to the

14. Install the bolts securing the exhaust system

dimension listed in substep g. This

mounting bracket (B, Figure 38) and tighten se-

will align the race with the bearing

curely.

outer race installed in the primary

15. Install the exhaust system as described in

chaincase. Installing the wrong race

Chapter Seven.

or installing it incorrectly will dam-

16. Test ride the motorcycle slowly and check for

age the bearing and race assembly.

proper transmission operation.

g. Hold the extension shaft and tighten the nut to

press the bearing inner race onto the

TRANSMISSION SHAFTS

mainshaft. The mainshaft and countershaft

nuts have left-hand threads. Turn the

This section describes service to the side door and

mainshaft nut counterclockwise to tighten it.

both transmission shaft assemblies.

Install the race so that its inside edge is

Refer to Figure 41.

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244

CHAPTER SIX

Transmission Disassembly

The transmission shaft assemblies must be par-

tially disassembled prior to removing both shafts

from the side door. Do not try to remove the shafts

with all of the gears in place.

Store all of the transmission gears, snap rings,

washers and split bearings in their order of removal.

The snap rings are very difficult to loosen and re-

move, even with high-quality snap ring pliers. A

heavy-duty type retaining ring pliers (H-D part No.

J-5586), or an equivalent, are recommended for this

procedure.

1. Remove the transmission side door and transmis-

sion shaft assemblies as described in this chapter.

2. Protect the splines and threads on the mainshaft

with tape or a plastic sleeve (Figure 42).

3. Remove the mainshaft second gear (Figure 43).

4. Remove the snap ring (Figure 44) from the

countershaft.

5. Remove the countershaft fifth gear (Figure 45).

6. Remove the countershaft second gear (Figure

46).

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TRANSMISSION

245

CAUTION

Do not expand the split bearings any

more than necessary to slide them off

the shaft. The bearing carriers are

plastic and will fracture if expanded

too far.

7. Remove the split bearing (Figure 47) from the

countershaft.

8. Slide off the washer and remove the snap ring

(Figure 48) from the countershaft.

9. Remove the countershaft third gear (Figure 49).

NOTE

The snap ring in Step 10 must be re-

leased and moved in order to gain ac-

cess to the snap ring on the other side

of the third gear.

10. Using snap ring pliers, release the snap ring

(Figure 50) behind the mainshaft third gear. Slide

the snap ring away from the third gear.

11. Slide the third gear toward the side door and re-

move the snap ring (Figure 51) and washer.

12. Remove the mainshaft third gear (Figure 52).

13. Remove the washer and snap ring (Figure 53).

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246

CHAPTER SIX

14. Remove the split bearing (Figure 54) from the

mainshaft.

15. Place a brass or aluminum washer (Figure 55)

between the countershaft fourth gear and the

mainshaft fourth gear. This will lock both transmis-

sion shafts from rotation.

16. Loosen and remove the locknuts and washers

(Figure 56) securing the shaft assemblies to the side

door. Remove the brass or aluminum washer. New

locknuts must be installed during assembly.

17. Press the countershaft out of its side door bear-

ing as follows:

a. Support the countershaft first gear on a tube

(A, Figure

57) in a press so that the

countershaft can be pressed out without any

interference. Center the countershaft under

the press ram.

b. Place a mandrel (B, Figure 57) on top of the

countershaft and press the countershaft out of

the side door.

18. Remove the spacer (A, Figure 58), fourth gear

(B), first gear

(D) from the

countershaft.

19. Remove the split bearing (A, Figure 59) from

the countershaft.

20. If necessary, remove the snap ring (B, Figure

59) from the countershaft.

21. Remove the first gear (Figure 60) from the

mainshaft.

22. Remove the snap ring and washer (A, Figure

61) from the mainshaft.

23. Press the mainshaft out of its side door bearing

as follows:

a. Support the mainshaft fourth gear on a tube

(A, Figure 62) in a press so that the mainshaft

can be pressed out without any interference.

Center the mainshaft under the press ram.

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TRANSMISSION

247

b. Place a mandrel (B, Figure 62) on top of the

mainshaft and press the mainshaft out of the

side door.

24. From the mainshaft, remove the fourth gear and

spacer (B, Figure 61).

25. Inspect all parts as described in this section.

Transmission Inspection

Maintain the alignment of the transmission com-

ponents when cleaning and inspecting the individ-

ual parts in the following section. To prevent

intermixing parts, work on only one shaft at a time.

Refer to Table 2 and inspect the service clearance

and end play of the indicated gears and shafts. Re-

place parts that show excessive wear or damage as

described in this section.

CAUTION

Do not clean the split bearings in sol-

vent. It is difficult to remove all traces

of solvent from the bearing plastic re-

tainers. Flush the bearings clean with

new transmission oil.

1. Clean and dry the shaft assembly.

2. Inspect the mainshaft and countershaft for:

a. Worn or damages splines (A, Figure 63).

b. Excessively worn or damaged bearing sur-

faces.

c. Cracked or rounded-off snap ring grooves (B,

Figure 63).

d. Worn or damaged threads (C, Figure 63).

3. Check each gear for excessive wear, burrs, pit-

ting, and chipped or missing teeth. Check the inner

splines (Figure 64) on sliding gears and the bore on

stationary gears for excessive wear or damage.

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248

CHAPTER SIX

4. Check the gear bushings (Figure 65) for wear,

cracks or other damage.

5. To check stationary gears for wear, install them

on their correct shaft and in the original operating

position. If necessary, use the old snap rings to se-

cure them in place. Then spin the gear by hand.

The gear should turn smoothly. A rough turning

gear indicates heat damage—check for a dark blue

color or galling on the operating surfaces. Rocking

indicates excessive wear, either to the gear or shaft

or both.

6. To check the sliding gears, install them on their

correct shaft and in their original operating position.

The gear should slide back and forth without any

binding or excessive play.

7. Check the shift fork slot (Figure 66) for wear or

damage.

8. Check the dogs on the gears for excessive wear,

rounding, cracks or other damage. Refer to Figure

67. When wear is noticeable, make sure it is consis-

tent on each gear dog. If one dog is worn more than

the others, the others will be overstressed during op-

eration and will eventually crack and fail. Check en-

gaging gears as described in Step 9.

9. Check each gear dog slot for cracks, rounding

and other damage. Check engaging gears as de-

scribed in Step 6.

10. Check engaging gears by installing the two

gears on their respective shafts and in their original

operating position. Mesh the gears together. Twist

one gear against the other and then check the dog

engagement. Then reverse the thrust load to check

in the other operating position. Make sure the en-

gagement in both directions is positive and without

any slippage. Check that there is equal engagement

across all of the engagement dogs.

NOTE

When there is excessive or uneven

wear to the gear engagement dogs,

check the shift forks carefully for

bending and other damage. Refer to

Shifter Adjustment in this chapter.

NOTE

Replace defective gears along with

their mating gears, though they

may not show as much wear or dam-

age.

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TRANSMISSION

249

3. Remove both snap rings (Figure 73) from the

outer surface of the side door.

4A. If the special tool set is used, follow the manu-

facturer’s instructions and remove the bearings.

4B. If a press is used, perform the following:

a. Support the side door on the press bed with

the outer surface facing up.

b. Use a driver or socket and press the bearing

out of the backside of the side door.

c. Repeat for the opposite bearing.

5. Clean the side door again in solvent and dry thor-

oughly.

11. Check the spacers (Figure 68) for wear or dam-

6. Inspect the bearing bores in the side cover for

age.

cracks or other damage. Replace the side door if

12. Check the split bearings (Figure 69) for exces-

damaged.

sive wear or damage.

13. Replace all of the snap rings during reassembly.

NOTE

In addition, check the washers for burn marks, scor-

Both side door bearings have the

ing or cracks. Replace as necessary.

same part number.

7A. If the special tool set is used, follow the manu-

Side Door Bearings

facturer’s instructions and install the bearings.

Inspection and Replacement

7B. If a press is used, perform the following:

a. Support the side door in a press with the back-

The side door bearings are pressed into place and

side facing up.

secured with a snap ring. They can be removed and

installed using a special transmission door bearing

b. Install bearings with their manufacturer’s

remover and installer tool set (JIMS part No. 1078)

marks facing out.

(Figure 70). If the special tool set is not available, a

c. Use a driver that matches the bearing outer

press is required.

race. Press the bearing into the side door until

Refer to Figure 71.

it bottoms.

1. Clean the side door and bearings in solvent and

d. Repeat for the opposite bearing.

dry with compressed air.

8. Position the beveled snap ring with the sharp

2. Turn each bearing inner race (Figure 72) by

side facing toward the bearing outer race and install

hand. The bearings must turn smoothly.

the snap ring. Make sure the snap ring is correctly

If replacement is necessary, continue to Step 3.

seated in the side door groove (Figure 73).

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250

CHAPTER SIX

TRANSMISSION CASE BEARINGS AND COVERS

Locating pin

Transmission case

Mainshaft

bearing-left side

Snap ring

Quad seal

Oil seal

Sprocket spacer

Spacer (1999-2000)

Bearing

10.

Transmission side

door

11.

Gasket

12.

Bolt

13.

Bolt

14.

Locknut

15.

Washer

16.

Bolt

17.

Bolt

18.

Washer

19.

Bolt

20.

Washer

21.

Harness retainer

22.

Gasket

23.

Coupling

24.

Ball (3)

25.

Inner ramp

26.

Filler plug/dipstick

27.

O-ring

28.

Clutch release

cover

29.

Bolt

30.

Clutch cable

31.

Plug

32.

Outer ramp

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TRANSMISSION

251

TRANSMISSION

1. Mainshaft first gear

2. Mainshaft

3. Snap ring

4. Thrust washer

5. Mainshaft third gear

6. Mainshaft second gear

7. Bearings

8. Oil slinger assembly

9. Clutch pushrod

10. Locknut

11. Washer

12. Side door

13. Gasket

14. Spacer

15. Mainshaft fourth gear

16. Spacer

17. Countershaft fourth

gear

18. Countershaft first gear

19. Countershaft

20. Countershaft third gear

21. Countershaft second

gear

22. Countershaft fifth gear

Transmission Assembly

Refer to Figure 74.

CAUTION

Install a new snap ring at every loca-

tion to ensure proper gear alignment

and engagement. Never reinstall a

snap ring that has been removed,

since it has become distorted and

weakened and may fail. Make sure

each new snap ring is correctly seated

in its respective shaft groove.

1. Apply a light coat of clean transmission oil to all

mating gear surfaces and to all split bearing halves

before assembly.

2. If removed, install the side door bearings as de-

scribed in this chapter.

3. Onto the mainshaft, install the following:

a. If removed, install the new snap ring (Figure

75).

b. Position the first gear with the shift dog side

going on last and install the first gear (Figure

76).

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252

CHAPTER SIX

c. Install the snap ring

(A, Figure 77) and

washer (B).

d. Install the split bearing (Figure 78).

e. Position the fourth gear with the shift dog side

going on first and install the fourth gear (Fig-

ure 79).

f. Position the spacer with the beveled side fac-

ing out (Figure 80) and install the spacer.

4. Onto the countershaft, install the following:

a. If removed, install the new snap ring (A, Fig-

ure 81).

b. Install the washer (B, Figure 81) and push it

against the snap ring.

c. Install the split bearing (Figure 82).

d. Position the first gear with the shoulder side

(Figure 83) going on last and install the first

gear onto the split bearing (Figure 84).

e. Position the fourth gear with the wide shoul-

der (Figure 85) going on first and install the

fourth gear.

f. Position the spacer with the beveled side fac-

ing out (Figure 86) and install the spacer.

5. Apply transmission oil to the inner race of both

bearings and onto the shoulder of both shaft assem-

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TRANSMISSION

253

blies. Also apply transmission oil to the inner

threads and ends of the special tools used in Step 8.

6. Position the countershaft (A, Figure 87) on the

left side of the side door. Position the mainshaft (B,

Figure 87) on the right side of the side door.

7. Mesh the two shaft assemblies together and start

them into the side door bearings (Figure 88).

8. Attach the shaft installers (JIMS part No. 2189)

onto the ends of both shafts.

9. Tighten the special tools (Figure 89), alternating

between both shafts, until both shaft shoulders bot-

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254

CHAPTER SIX

tom on the inner race of the side door bearings (Fig-

ure 90).

10. Unscrew and remove the special tools.

CAUTION

Always install new locknuts. If an old

locknut is reinstalled, it may work

loose, resulting in costly transmission

damage.

11. Install the spacers

(A, Figure 91) and new

locknuts (B).

12. Start the new locknuts by hand until the locking

portion of the nut touches the end of the transmis-

sion shaft.

13. Place a brass or aluminum washer (Figure 55)

between the countershaft fourth gear and the

mainshaft fourth gear. This will lock both transmis-

sion shafts.

14. Tighten the locknuts (Figure 92) to the specifi-

cation in Table 3.

15. Onto the mainshaft, install the following:

a. Install the split bearing (Figure 93).

b. Move the snap ring (A, Figure 94) installed in

Step 3 out of the groove and toward the first gear.

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TRANSMISSION

255

100

101

c. Install the washer (B, Figure 94) and slide it

against the snap ring (A, Figure 95).

d. Position the third gear with the shift dogs side

(B, Figure 95) going on last. Install the third

gear onto the split bearing (Figure 96).

e. Install the washer (A, Figure 97) and snap

ring (B). Make sure the snap ring is correctly

seated in the mainshaft groove.

f. Move the third gear away from the first gear

and up against the washer and snap ring in-

stalled in sub-step e.

g. Reposition the washer and snap ring (A, Fig-

ure

95) behind the third gear into the

mainshaft groove. Make sure the snap ring is

correctly seated in the mainshaft groove.

16. Onto the countershaft, install the following:

a. Position the third gear with the shift fork

groove (Figure 98) side going on last and in-

stall the third gear.

b. Install the circlip (A, Figure 99) and washer

(B).

c. Install the split bearing (Figure 100).

d. Position the second gear with the shift dog

side (Figure 101) going on first. Install the

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256

CHAPTER SIX

102

105

103

106

104

107

second gear onto the split bearing (Figure

102).

108

17. Onto the mainshaft, position the second gear

with the shift fork groove (Figure 103) side going

on first and install the second gear (Figure 104).

18. Onto the countershaft, install the fifth gear

(Figure 105), then install the snap ring (Figure

106). Make sure the snap ring is correctly seated in

the countershaft groove.

19. Refer to Figure 107 for correct placement of all

gears. Also check that the gears mesh properly to

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TRANSMISSION

257

109

MAIN DRIVE GEAR

1. Bearing

6. Snap ring

2. Main drive gear

7. Quad seal

3. Transmission case

8. Oil Seal

4. Bearing

9. Sprocket spacer

5. Mainshaft bearing-

left side

the adjoining gear where applicable. This is the last

Removal

chance prior to installing the shaft assemblies into

the transmission case. Make sure they are correctly

1. Remove the transmission shaft assemblies from

assembled.

the transmission case as described in this chapter.

2. Remove the spacer from the main drive gear oil

seal.

MAIN DRIVE GEAR

3. Remove the snap ring behind the bearing.

The main drive gear and bearing assembly are

NOTE

pressed into the transmission case. If the transmis-

If the main drive gear will not loosen

sion case is installed in the frame, a special trans-

from the bearing in Step 4 due to cor-

mission main drive gear tool set (JIMS part No.

rosion, remove the special tools and

35316-80) is required to remove the main drive gear

heat the bearing with a heat gun.

(Figure 108). If the transmission has been removed,

use a press to remove and install the main drive

4. Assemble the special tool set onto the main drive

gear.

gear following the manufacturer’s instructions.

Whenever the main drive gear is removed, the

Then tighten the puller nut slowly to pull the main

main drive gear bearing must be replaced at the

drive gear from the bearing in the transmission case.

same time.

5. Remove the main drive gear bearing from the

Refer to Figure 109.

transmission case as described in this section.

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258

CHAPTER SIX

Inspection

110

1. Clean the main drive gear in solvent and dry with

compressed air, if available.

2. Check each gear tooth (A, Figure 110) for ex-

cessive wear, burrs, galling and pitting. Check for

missing teeth.

3. Check the gear splines (B, Figure 110) for ex-

cessive wear, galling or other damage.

4. Inspect the two main drive gear needle bearings

for excessive wear or damage. Refer to Figure 111

and Figure 112. Insert the mainshaft into the main

drive gear to check bearing wear. If necessary, re-

place the bearings as described in this section.

111

Main Drive Gear Needle Bearing

Replacement

Both main drive gear needle bearings must be in-

stalled to the correct depth within the main drive

gear. The correct depth is obtained with the use of a

main drive gear bearing tool

(JIMS part No.

37842-91). This tool is also used to install the oil

seal. If this tool is not available, a press is required.

If this tool is not available, measure the depth of

both bearings before removing them.

Replace both main drive gear needle bearings as a

112

set.

CAUTION

Never re-install a main drive gear

needle bearing, as it was distorted

during removal.

1. Remove the oil seal (Figure 113) from the clutch

side of the main drive gear.

2. If the special tool is not used, measure and re-

cord the depth of both bearings.

3. Support the main drive gear in a press and press

out one needle bearing. Then turn the gear over and

press out the opposite bearing.

113

4. Clean the gear and its bearing bore in solvent and

dry thoroughly.

5. Apply transmission oil to the bearing bore in the

main drive gear and to the outer surface of both

bearings.

NOTE

Install both needle bearings with their

manufacturer’s name and size code

facing out.

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TRANSMISSION

259

installation tool, with the short side facing

114

down (Figure 115), inserted into the bearing.

Operate the press until the tool’s shoulder

bottoms against the gear.

c. Turn the main drive gear over so that the inner

end faces up. Align the new bearing with the

main drive gear and place the installation

tool, with the long side facing down, inserted

into the bearing. Operate the press until the

tool’s shoulder bottoms against the gear.

6B. If the bearings are being installed without the

installation tool, use a suitable mandrel and press in

the bearing to the depth recorded in Step 2.

7. Install a new oil seal (Figure 113) into the clutch

115

side of the main drive gear.

Main Drive Gear Bearing Replacement

The main drive gear bearing (Figure 109) is

pressed into the transmission case. If the transmis-

sion case is installed in the frame, a transmission

main bearing remover set (JIMS part No. 1720)

(Figure 116), or equivalent, is required to remove

the main drive gear bearing.. If the transmission has

been removed, use a press to remove the main drive

gear bearing.

Whenever the main drive gear is removed, the

116

main drive gear bearing is damaged and must be re-

placed at the same time.

CAUTION

Failure to use the correct tools to install

the bearing will cause premature fail-

ure of the bearing and related parts.

1. Remove the main drive gear from the transmis-

sion case as described in this chapter.

2. Assemble the special tool set onto the main drive

gear bearing following the manufacturer’s instruc-

6A. To install the bearings with the special tool, per-

tions. Then tighten the bolt and nut slowly to pull the

form the following steps:

main drive gear bearing from the transmission case.

3. Clean the bearing bore and dry with compressed

a. The special tool has two different length ends.

air. Check the bore for nicks or burrs. Check the

The tool’s long side (A, Figure 114) is for the

snap ring groove for damage.

clutch side of the main drive gear (Figure

112). The tool’s short side (B, Figure 114) is

NOTE

for the transmission side of the main drive

Install the bearing into the transmis-

gear (Figure 111).

sion case with the bearing manufac-

turer’s name and size code facing out.

b. Install the main drive gear in a press with the

transmission end facing up. Align the new

4. Apply transmission oil to the bearing bore in the

bearing with the main drive gear and place the

transmission case and to the outer surface of the

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 13