Removing Oil Seal

Shift transmission into low gear and lock rear wheel brake to prevent parts from turning while disassembling.

Remove outer front chain guard, engine sprocket, front chain, clutch assembly, inner chain guard, transmission sprocket and rear chain.

Place sleeve (C, Figure 4-7) on end of main drive gear. Slide body (B) over sleeve with body stop rod downward. Turn body clockwise until stop bears against transmission case or mounting plate. Hold body in this position and insert center punch (E) through each of the three holes in body and center punch oil seal as shown in Figure 4-8.

Remove body and drill a 3/32 in. hole through metal face of oil seal at each punch mark. Replace body and insert the three self-tapping screws (D) through body and into oil seal. Tighten screws until body is against oil seal.

Turn actuating screw (A) into body and continue turning as shown in Figure 4-10 until oil seal is free. Discard oil seal and oil seal cork washer found behind seal.

Figure 4-10. Pulling Oil Seal

Figure 4-8. Ceriterpunching Screw Hole Locations

Figure 4-9. Installing Oil Seal INSTALLING OIL SEAL

Remove burrs with scraper from outer edge of oil seal recess in transmission where metal was staked to secure seal. Position new cork gasket.

Apply a light coat of Harley-Davidson "Gasket Eliminator Sealant," Part No. 99633-77 to the outside diameter of the new seal. Coat lip of oil seal with oil or grease to prevent damage to new seal.

Insert sleeve (C, Figure 4-7) into oil seal. Place sleeve and seal on main drive gear with lip side of seal toward transmission case. Turn seal so it will not stake at same points old seal was staked.

Figure 4-10. Pulling Oil Seal

Place body on sleeve and turn actuating screw into body as far as it will go without pulling body away from seal. Install mainshaft clutch hub nut and turn it in against actuating screw as shown in Figure 4-9. Back out actuating screw until body has pushed oil seal into place and body is tight against end of gear box.

Take care not to plug the oil hole at the base of recess with sealant.

Remove tool and stake case into notches in seal.

After assembly is complete, check clutch control adjustment.

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