Improper tightening of sprocket nut can cause drive component damage. (00541b)
Installing Main Drive Gear Bearing
NOTE
CROSS PLATE (Part No. HD-35316-3A) will retrofit to earlier transmissions. Note that one end of cross plate is stamped, “UP 6 SPEED”. Mount cross plate with this end pointing up for 6 speed transmissions.
1. See Figure 6-49. Secure CROSS PLATE (Part No. HD-35316-3A) (2) on right side of transmission case with two screws (3). Position cross plate with large bolt hole aligned with center of main drive gear bearing bore.
2. Apply a light coat of graphite lubricant to the threads of 12 IN. BOLT (Part No. HD-35316-5) (1) and install through cross plate and main drive gear bearing bore.
3. Place main drive gear bearing (4), BEARING DRIVER (Part No. HD-35316-8) (5), BEARING (6), FLAT WASHER (7) and NUT (8) over end of bolt.
4. Tighten nut until main drive gear bearing bottoms against lip cast into transmission case bearing bore.
Installing Main Drive Gear
NOTE
See Figure 6-50. Make sure new O-ring (4) is installed onto
main drive gear (3). Lubricate O-ring with clean engine oil.
1. See Figure 6-50. Apply a light coat of graphite lubricant to the threads of 8 IN. BOLT (Part No. HD-35316-4A) (1) and insert through WASHER (Part No. HD-35316-7) (2) and main drive gear (3). Insert assembly into transmission case, through main drive gear bearing.
2. Place INSTALLER CUP (Part No. HD-35316-12) (5), BEARING (6), FLAT WASHER (7) and NUT (8) over end of bolt.
3. Tighten nut until main drive gear contacts main drive gear bearing.
NOTE
See Figure 6-51. Retaining ring must be installed with the flat side facing the bearing and the opening within the ninety degree range shown.
4. See Figure 6-52. Install new retaining ring (2).
Installing Main Drive Gear Large Seal
1. See Figure 6-52. Install PILOT (Part No. HD-47856-2) over end of main drive gear bearing inner race.
2. Coat lips of new main drive gear seal with transmission lubricant.
3. See Figure 6-53. Place seal over pilot with garter spring facing bearing, and position seal squarely in end of crankcase bore.
NOTE
ADAPTER (Part No. HD-47856-3) and main drive gear have right-hand threads.
4. See Figure 6-54. Install ADAPTER (Part No. HD-47856-3) onto end of main drive gear until it contacts main drive gear.
5. See Figure 6-55. Slide INSTALLER (Part No. HD-47856-1) (1) over adapter until cupped end of installer is flat against seal.
6. Install NUT (Part No. HD-47856-6) (2) onto end of adapter against installer.
7. See Figure 6-56. Hold adapter from rotating and tighten large nut with CROW’S FOOT WRENCH (Part No. HD-47856-7) (1) attached to a 1/2 in breaker bar (2) until outer face of seal is flush with outer edge of transmission bore.
NOTE
Seal depth will be controlled by tool. Seal can be recessed as much as 0.030 in. (0.762 mm) below outer edge of bore.
8. Remove nut, installer, adapter and pilot.
9. Install bearing housing and transmission components. See 6.8 TRANSMISSION ASSEMBLY, Installation.
10. Install sprocket and drive belt. See 5.9 TRANSMISSION SPROCKET. Do not adjust belt at this time.
11. Install the bearing inner race on the transmission mainshaft. See 6.8 TRANSMISSION ASSEMBLY, Assembly.
12. Install the primary chaincase housing. See 5.5 PRIMARY CHAINCASE HOUSING, Installation.
13. Install the clutch assembly, primary chain, chain tensioner assembly and compensating sprocket components. See 5.4 DRIVE COMPONENTS, Installation.
14. Install the primary chaincase cover. See 5.3 PRIMARY CHAINCASE COVER, Installation.
15. Adjust the drive belt. See 1.14 DRIVE BELT AND SPROCKETS, Setting Belt Deflection.
16. Install exhaust system. See 4.18 EXHAUST SYSTEM.
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