NOTE
Leave transmission case in the frame unless the case it self must be replaced. For illustration purposes, some photographs may show the case removed.
1. Remove exhaust system. See 4.18 EXHAUST SYSTEM.
2. Remove primary chaincase cover, clutch assembly, primary chain, compensating sprocket, and primary chaincase and remove bearing inner race from the transmission mainshaft. See 5.5 PRIMARY CHAINCASE HOUSING.
3. Remove transmission bearing housing. See 6.8 TRANSMISSION ASSEMBLY.
NOTE
Main drive gear and bearing can be removed with the transmission case in the frame after removing bearing housing. Use MAIN DRIVE GEAR/BEARING REMOVER AND INSTALLER (Part No. HD-35316-C).
4. Remove retaining ring.
NOTES
• The main drive gear bearing and retaining ring must be replaced if the main drive gear is removed. The bearing will be damaged during the removal procedure.
• The CROSS PLATE (Part No. HD-35316-3A) is stamped, “UP 6 SPEED”. Mount cross plate with this end pointing up.
5. See Figure 6-38. Place CROSS PLATE (Part No. HD-35316-3A) (1) on right side of transmission case as shown, and secure with two screws (2). Position cross plate so that large bolt hole in cross plate is lined up with center of main drive gear (4).
6. Apply a light coat of graphite lubricant to the threads of the 12 IN. BOLT (Part No. HD-35316-5) (3) and insert through cross plate and main drive gear.
7. At left side of transmission case, place WASHER (Part No. HD-35316-7), BEARING (Part No. RS-25100-200) (6), flat washer (7) and nut (8) over end of bolt. Tighten nut until main drive gear is free.
NOTES
• When removing the main drive gear, the gear is pressed out against the resistance of the bearing 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.
• See Figure 6-39. When the main drive gear is removed, a portion of the bearing inner race remains attached to the main drive gear. If the main drive gear is to be reused, this inner race must be removed first.
8. Remove tool and remove gear from gearcase.
9. See Figure 6-39. Use WEDGE ATTACHMENT (Part No. HD-95637-46B) and LONG BOLTS (Part No. HD-95637-10) to remove inner race from main drive gear.
10. Remove large main drive gear oil seal.
11. Remove retaining ring from bearing bore.
12. See Figure 6-40. Slide PILOT (Part No. HD-35316-10) (3) over small end of BEARING DRIVER (Part No. HD-35316-9) (2).
13. Apply a light coat of graphite lubricant to the threads of the 8 IN. BOLT (Part No. HD-35316-4A) (1) and insert through bearing driver and pilot.
14. Insert bolt with bearing driver and pilot into right side of transmission case, through main drive gear bearing (4). Make sure bearing driver fits up against main drive gear bearing and pilot is centered in bearing bore.
15. At left side of case, slide RECEIVER CUP (Part No. HD-35316-11) (5) onto bolt and over main drive gear bearing.
Install BEARING (Part No. RS-25100-200) (6), flat washer (7) and nut (8) over end of bolt.
NOTE
Support bearing remover assembly as you remove bearing in the following step. Entire assembly will fall out of transmission case when bearing comes free.
16. Tighten nut until main drive gear bearing is free.
17. Discard main drive gear bearing.
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