Service Tool Instructions

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1 Service Tool Instructions REV Instruction Sheet ID: -J0 HD--C MAIN DRIVE GEAR/BEARING REMOVER AND INSTALLER SET General This instruction sheet describes the use of the HD--C Main Drive Gear/Bearing Remover and Installer Set. This tool set is used for removing and installing main drive gears and bearings on all 00 and later Sportster, Dyna and Buell motorcycles. Refer to earlier instruction sheets or applicable service manual for procedures pertaining to previous models. A Service Manual for your model motorcycle is available from your Harley-Davidson Dealer. Removing Main Drive Gear Sportster/Buell If not already done, remove small oil seal in end of main drive gear.. See Figure. Place CROSS PLATE (Part No. B-) () on mating surface of right crankcase as shown. Position cross plate so that roll pins () fit into crankcase mating screw holes and bolt hole (9) in cross plate is centered over main drive gear ().. Insert IN. BOLT (Part No. HD--A) () through cross plate and main drive gear.. At outside of case, place WASHER (Part No. HD-- ) (), NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. Tighten nut until main drive gear is free. 9. Cross plate (Part No. B-). Roll pin (). in. bolt (Part No. HD--A). Main drive gear. Washer (Part No. HD--). Nice bearing (Part No. RS-00-00) 9. Bolt hole Figure. Removing Main Drive Gear Sportster/Buell (Sportster Crankcase Shown) Form # HD--0 SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- of

2 S 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. 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 re-used, this inner race must be removed first. Removing Main Drive Gear Bearing Sportster/Buell If not already done, remove large main drive gear oil seal and retaining ring.. See Figure. From inside crankcase, position BEARING DRIVER (Part No. HD--9) () over main drive gear bearing.. Insert IN. BOLT (Part No. HD--A) () through bearing driver and bearing.. At outside of case, slide RECEIVER CUP (Part No. HD- -) () onto bolt and over bearing. Install NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. 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 bearing is free.. Discard main drive gear bearing.. Main drive gear. Inner bearing race (not visible in this photo). Bearing race puller (Part no. HD-9-B). Press ram Figure. Removing Inner Bearing Race From Main Drive Gear Sportster/Buell 0 0. in. Bolt (Part No. HD--A). Bearing driver (Part No. HD--9). Main drive gear bearing. Receiver cup (Part No. HD--). Nice bearing (Part No. RS-00-00). Flat washer. Nut Figure. Removing Main Drive Gear Bearing Sportster/Buell (Sportster Crankcase Shown) SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

3 Installing Main Drive Gear Bearing Sportster/Buell. See Figure. Place CROSS PLATE (Part No. B-) () on mating surface of right crankcase as shown. Position cross plate so that roll pins () fit into crankcase mating screw holes and bolt hole (9) in cross plate is centered over crankcase bearing bore (0).. Insert IN. BOLT (Part No. HD--A) () through cross plate and main drive gear bearing bore.. At outside of case, place main drive gear bearing (), BEARING DRIVER (Part No. HD--) (), NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. CAUTION 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 Cross plate (Part No. B-). Roll pin (). in. bolt (Part No. HD--A). Main drive gear bearing. Bearing driver (Part No. HD--). Nice bearing (Part No. RS-00-00) 9. Bolt hole 0. Crankcase bearing bore Figure. Installing Main Drive Gear Bearing Sportster/Buell (Sportster Crankcase Shown) SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

4 Installing Main Drive Gear Sportster/Buell See Figure. Make sure to install new O-ring () onto main drive gear () and lubricate O-ring with clean engine oil before installing drive gear into crankcase.. See Figure. Insert IN. BOLT (Part No. HD--A) () through WASHER (Part No. HD--) () and main drive gear (). Insert assembly through main drive gear bearing in crankcase.. At outside of case, place INSTALLER CUP (Part No. HD- -) (), NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. Tighten nut until main drive gear bottoms against main drive gear bearing. Removing Main Drive Gear Dyna CROSS PLATE (Part No. HD--A) will retrofit to earlier Dyna model transmissions. Note that one end of cross plate is stamped, UP SPEED. Mount cross plate with this end pointing up for 00 and later Dyna models with six-speed transmissions. The other end of the cross plate is stamped, UP SPEED. Mount cross plate with this end pointing up for 00 and earlier Dyna models with five-speed transmissions.. See Figure. Place CROSS PLATE (Part No. HD- -A) () on right side of transmission case as shown, and secure with two screws (). Position cross plate so that large bolt hole in cross plate is lined up with center of main drive gear ().. Insert IN. BOLT (Part No. HD--) () through cross plate and main drive gear.. At left side of transmission case, place WASHER (Part No. HD--) (), NICE BEARING (Part No. RS ) (), FLAT WASHER () and NUT () over end of bolt. Tighten nut until main drive gear is free in. bolt (Part No. HD--A). Washer (Part No. HD--). Main drive gear. O-ring. Installer cup (Part No. HD--). Nice bearing (Part No. RS-00-00) Figure. Installing Main Drive Gear Sportster/Buell (Sportster Crankcase Shown). Cross plate (Part No. HD--A). Screw (). in. bolt (Part No. HD--). Main drive gear. Washer (Part No. HD--). Nice bearing (Part No. RS-00-00) Figure. Removing Main Drive Gear Dyna SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

5 S 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. 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 re-used, this inner race must be removed first. Removing Main Drive Gear Bearing Dyna If not already done, remove large main drive gear oil seal and retaining ring.. See Figure. Slide PILOT (Part No. HD--0) () over small end of BEARING DRIVER (Part No. HD- -9) ().. Insert IN. BOLT (Part No. HD--A) () through bearing driver and pilot.. Insert bolt with bearing driver and pilot into right side of transmission case, through main drive gear bearing (). Make sure bearing driver fits up against main drive gear bearing and pilot is centered in bearing bore.. At left side of case, slide RECEIVER CUP (Part No. HD- -) () onto bolt and over main drive gear bearing. Install NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. Support bearing remover assembly as you remove bearing in the following step. Entire assembly will fall out of transmission case when bearing comes free.. Tighten nut until main drive gear bearing is free.. Discard main drive gear bearing.. Main drive gear. Inner bearing race (not visible in this photo). Bearing race puller (Part no. HD-9-B). Press ram Figure. Removing Inner Bearing Race From Main Drive Gear Dyna. in. Bolt (Part No. HD--A). Bearing driver (Part No. HD--9). Pilot (Part No. HD--0). main drive gear bearing. Receiver cup (Part No. HD--). Nice bearing (Part No. RS-00-00) Figure. Removing Main Drive Gear Bearing Dyna SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

6 Installing Main Drive Gear Bearing Dyna CROSS PLATE (Part No. HD--A) will retrofit to earlier Dyna model transmissions. Note that one end of cross plate is stamped, UP SPEED. Mount cross plate with this end pointing up for 00 and later Dyna models with six-speed transmissions. The other end of the cross plate is stamped, UP SPEED. Mount cross plate with this end pointing up for 00 and earlier Dyna models with five-speed transmissions.. See Figure 9. Place CROSS PLATE (Part No. HD- -A) () on right side of transmission case as shown, and secure with two screws (). Position cross plate so that large bolt hole in cross plate is lined up with center of main drive gear bearing bore in left side of transmission case.. Insert IN. BOLT (Part No. HD--) () through cross plate and main drive gear bearing bore.. At outside of case, place main drive gear bearing (), BEARING DRIVER (Part No. HD--) (), NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. CAUTION 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 transmission case bearing bore in. bolt (Part No. HD--). Cross plate (Part No. HD--A). Screw (). Main drive gear bearing. Bearing driver (Part No. HD--). Nice bearing (Part No. RS-00-00) Figure 9. Installing Main Drive Gear Bearing Dyna SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

7 Installing Main Drive Gear Dyna See Figure 0. Make sure to install new O-ring () onto main drive gear () and lubricate O-ring with clean engine oil before installing drive gear into transmission case.. See Figure 0. Insert IN. BOLT (Part No. HD-- A) () through WASHER (Part No. HD--) () and main drive gear (). Insert assembly into transmission case, through main drive gear bearing.. At outside of case, place INSTALLER CUP (Part No. HD- -) (), NICE BEARING (Part No. RS-00-00) (), FLAT WASHER () and NUT () over end of bolt. Tighten nut until main drive gear bottoms against main drive gear bearing.. in. bolt (Part No. HD--A). Washer (Part No. HD--). Main drive gear. O-ring. Installer cup (Part No. HD--). Nice bearing (Part No. RS-00-00) Figure 0. Installing Main Drive Gear Dyna SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

8 Service Tool Service Parts Part No. HD--C Main Drive Gear/Bearing Remover and Installer Set Date /0 HD--C 9 0 Item Description Part No.. Bearing driver HD--9. Installer cup HD--. Installer cup HD--. Bearing driver HD--. Receiver cup HD--. Nice bearing RS Pilot HD Bearing driver HD--. Washer HD--. in. bolt HD--A. in. bolt HD--. Cross plate B-9. Cross plate w/screws HD--A. Cross plate B-. Cross plate HD--9. Thread lubricant J--A SPX Corporation Eisenhower Drive Owatonna, MN Phone 00-- Fax -- -J0 of

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