Illus 64 1948 1954


1. Pinion gear. Gear and shaft are spline engaged and gear is a slip fit on shaft.

2. Cam gear. (Steel spacing washer behind this gear).

3. Breather gear.

4. Circuit breaker drive gear. (Spacing collar in front of this gear).

5. Intermediate gear (not itiarked). (Spacing collar in front of this gear).

6. Generator drive gear (not marked).

7. Oil pump drive gear (not marked); secured on end of pump drive shaft with key and spring ring.

Installing Timing Gear Case Cover (O.H.V. Engine)

Before installing cover, lay engine on its side and pour about Va pint of engine oil over timing gears.

Unless gear case cover gasket is in good condition, install a new "factory-made" gasket. Never use a "home-made" gasket as this gasket has holes especially located for oil passages and if a hole is left out or put in wrong place oiling system will not function normally. Install cover and all gear case cover screws. Tighten screws securely, and turn engine and note whether or not it turns freely. If new cam gear shaft bushings were installed and considerable drag is felt, it is very likely that the cam gear thrust washer may be too thick and must be ground thinner, to give cam gear from "free running" to

Cam Gear Shaft and Pinion Gear Shaft Bushings (O.H.V. Engine)

Check cam gear shaft bushing in right side crankcase, and cam gear shaft bushing and pinion gear shaft bushing in gear case cover for extent of wear. These bushings normally do not require renewal until an engine has run extremely high mileage. However, if engine has been run under dusty conditions without an air cleaner, or without giving proper attention to air cleaner if engine is so equipped, and considerable road dust has been taken into engine through carburetor, abnormal wear may be found at any mileage.

Specified clearance for cam gear shaft in cover bushing and crankcase bushing is .001" to .0015", and for pinion gear shaft in cover bushing is .0005" to .001". When bushings are worn to the extent of increasing clearance to .0025" or more, they should be renewed, as the cam gear is likely to become noisy with excessive clearance in these bushings. Worn bushing in case can be pushed out with an arbor press, supporting case on a suitable collar or sleeve at flanged end of bushing. Bushings in cover, must be pulled with Harley-Davidson special puller. Part No. 11952-36

Before removing old bushings, note location of oil transfer hole in pinion gear shaft bushing in timing gear case cover. New bushing must be installed with oil transfer hole in same location (transfer hole to line up with drilled oil passage in cover) as normal function of oiling system depends upon correct location of this hole. The cam gear shaft bushing in crankcase must be installed with oil slot in flange end of bushing upward.

Before pressing in new bushings note location of original dowel pin holes in crankcase and/or gear case cover for reference when drillincr new dowel pin holes. When drilling dowel pin holes in crankcase and/or gear case cover, be sure to locate holes Va" or more from original dowel pin holes.

When pressing in bushings be sure bushing flanges are seated tight against crankcase and or gear case cover.

After new bushings have been pressed in they must be dowel pinned to prevent them from turning.

by drilling a hole with a number 31 drill, 9/32" deep, through bushing flange and into aluminum so when dowel pin (Part No. 661-31) is driven in and bottomed, its end will be slightly below face of bushing flange. Peen bushing around dowel pin hole to prevent pin from coming out.

Oil hole for lubrication of cam shaft bushing in cover, will have to be drilled, with a 5/32" drill, using oil hole already in bushing boss as a drill guide.

After bushings have been pressed in, dowel pinned and necessary oil hole drilled, they must be line reamed with Harley-Davidson special reamers, Part Nos. 12134-36 and 12132-36. Cover must be installed and secured by at least four screws when line reaming bushings.

Line reaming pinion gear shaft bushing: Insert steel pilot bushing into crankcase roller race—insert Harley-Davidson special reamer. Part No. 12132-36, through pilot bushing, into pinion gear shaft bushing, and turn reamer until it bottoms in gear case cover. See Illus. 46.

Line reaming cam gear shaft bushings: Insert Harley-Davidson special reamer, Part No. 12134-36, through crankcase bushing, into cover bushing, and turn reamer until it bottoms in gear case cover.

illus. 46

line reaming pinion gear shaft bushing

Pinion Shaft—Late style pinion shaft is .0015 oversize when new. Use std. pinion gear. Pinion gear marked "P" is .0015+. (Late shaft identified by screw in outer end.)

Truing and Sizing Main Bearing Races

Before refitting worn main bearings, lap outer races to true them and remove any trace of wear shoulder at sides of roller paths using Harley-Davidson special lap, Part No. 11954-40 (see Illus. 48). Note: Before lap can be inserted in crankcase bushings, bearing washers, bearing spring rings and oil retaining bushing must be removed from the crankcase bushings. A race that is worn .0005" or more should be renewed.

When renewing main bearing races, heat cases (not over 300° F.) around races. Heating expands cases slightly and less force is required to press old races out and new races in. New races after installation, should also be lapped to smooth, true and align them, and to size them so that specified bearing clearance can be attained with roller sizes available.

When lapping main bearing races, right and left cases must be assembled and three or more studs illus. 46

line reaming pinion gear shaft bushing

Note: Illustration shows installation of reamer guide in crankcase to guide reamer when reaming bronze pinion shaft bushing in gear case cover. Cover must of course, be installed on right crankcase before starting the reaming operation. While illustration shows reaming Side Valve Engine pinion gear shaft bushing, same procedure is to be followed when reaming O.H.V. Engine pinion gear shaft bushing.

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