Counterbalancer Bearing Replacement

3.15

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Figure 3-156. Retaining Ring Removal

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PART NO.

SPECIALTY TOOL

HD-45311

Counterbalancer alignment pin

HD-45490

Balancer bearing remover/installer tools

HD-34902

Big-twin mainshaft primary bearing remover and installer

HD-95637

Wedge attachment

REMOVAL

Figure 3-154. Counterbalancer Gear Fastener

NOTE

Use Snap-on pliers SRPC3890 for removal/installation of the retaining rings.

Figure 3-156. Retaining Ring Removal

Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

4. See Figure 3-156. Remove outer retaining ring.

Figure 3-157. Counterbalancer Tool

1. See Figure 3-154. Install COUNTERBALANCER ALIGNMENT PIN (HD-45311). With the alignment mark in the 2 o'clock position, the case hole and the index hole in the counterbalancer will align.

2. Remove fastener and discard. The counterbalancer gear retaining fastener is one-time-use only. Always use a new fastener when installing counterbalancer gear.

Figure 3-157. Counterbalancer Tool

5. See Figure 3-157. Thread end of BALANCER BEARING REMOVER/INSTALLER TOOLS (HD-45490) into balancer shaft.

Figure 3-155. Counterbalancer Gear Removal

3. See Figure 3-155. Gently pry counterbalancer gear from shaft.

Awarning

9. See Figure 3-161. Remove inboard retaining ring.

Figure 3-162. Bearing Removal Insert

10. See Figure 3-162. Position the bearing removal insert as shown. Note the position of the flat.

Awarning

8. See Figure 3-160. Remove outboard inner retaining ring.

9320

Figure 3-158. Counterbalancer Outboard Bearing Removal

9320

Figure 3-158. Counterbalancer Outboard Bearing Removal

6. See Figure 3-158. The counterweight must be held in the position shown to prevent binding against the case. The tool will pull the outboard bearing and balancer through the case. When the bearing is free, remove tool and bearing.

Always wear proper eye protection when installing retaining rings. Use the correct retaining ring pliers. Verify that the tips of the pliers are not damaged or excessively worn. Slippage may propel the ring with enough force to cause eye injury.

8. See Figure 3-160. Remove outboard inner retaining ring.

Figure 3-161. Counterbalancer Inboard Retaining Ring

9. See Figure 3-161. Remove inboard retaining ring.

Figure 3-162. Bearing Removal Insert

10. See Figure 3-162. Position the bearing removal insert as shown. Note the position of the flat.

Figure 3-159. Counterbalancer Removal

7. See Figure 3-159. Counterbalancer can be removed from engine.

Figure 3-160. Outboard Inner Retaining Ring

Figure 3-163. Position Puller

11. See Figure 3-163. Thread puller rod into insert.

12. See Figure 3-164. Hold screw end of puller and turn large nut to remove the bearing.

NOTE

If counterbalancer bearings are being replaced, ALWAYS

replace the inner race.

13. See Figure 3-165. Use BIG-TWIN MAINSHAFT PRIMARY BEARING RACE REMOVER AND INSTALLER (HD-34902) and WEDGE ATTACHMENT (HD-95637) to remove inboard and outboard bearing inner races.

Figure 3-163. Position Puller

Figure 3-164. Remove Bearing

Figure 3-165. Remove Bearing Race

1. See Figure 3-166. Press new inner race of inboard bearing even with the end of the counterbalancer.

2. See Figure 3-167. Press new outboard bearing race flush against the shoulder of the balancer.

Inboard

Outboard

Figure 3-169. Inner Balancer Bearing Installation

Figure 3-168. Installed Inner Races

3. See Figure 3-168. Inboard bearing race is even with the end of the counterbalancer shaft. Outboard bearing race is fully seated against shoulder of counterbalancer.

NOTE

Use Harley-Davidson Motorcycle OH 20W50 to thoroughly lubricate bearing surfaces and case bores before bearing installation.

NOTE

When installing bearings, always drive/push against the side of the bearing with the manufactures lettering/part number.

Figure 3-166. Inboard Bearing Race

Figure 3-169. Inner Balancer Bearing Installation

4. See Figure 3-169. Using the bearing installer from the BALANCER BEARING REMOVER/INSTALLER TOOLS (HD-45490) drive the inner counterbalancer bearing into the case with a soft faced hammer, until the retaining ring groove is visible.

Figure 3-167. Outboard Bearing Race

9330

Figure 3-168. Installed Inner Races

9330

Inboard

Outboard

7. See Figure 3-172. Position counterbalancer in case.

Figure 3-171. Outboard Bearing Inner Retaining Ring Installation

6. See Figure 3-171. Install outboard bearing inner retaining ring. Be certain retaining ring is fully seated.

Figure 3-170. Inner Balancer Bearing Installation

5. See Figure 3-170. Install inner retaining ring. Be certain retaining ring is fully seated.

Figure 3-171. Outboard Bearing Inner Retaining Ring Installation

6. See Figure 3-171. Install outboard bearing inner retaining ring. Be certain retaining ring is fully seated.

Figure 3-172. Position Counterbalancer

NOTE

Use Harley-Davidson Motorcycle Oil 20W50 to thoroughly lubricate bearing surfaces and case bores before bearing installation process. Use Lubriplate No. 105 Assembly Grease (NAPA Part No. 765-2651) on inner races.

7. See Figure 3-172. Position counterbalancer in case.

Figure 3-173. Insert Tapered Guide

NOTE

When installing bearings, always drive/push against the side of the bearing with the manufactures lettering/part number.

8. See Figure 3-173. Start bearing by hand. Insert tapered guide from the BALANCER BEARING REMOVER/ INSTALLER TOOLS (HD-45490).

Figure 3-174. Outboard Bearing Installation

Figure 3-176. Counterbalancer Gear Master Tooth Flat

Figure 3-174. Outboard Bearing Installation

9. See Figure 3-174. Use the driver from the BALANCER BEARING REMOVER/INSTALLER TOOLS (HD-45490). Drive the bearing in with a soft faced hammer until the retaining ring groove is exposed.

Figure 3-176. Counterbalancer Gear Master Tooth Flat

11. See Figure 3-176. Note the position of the counterbalancer master tooth flat. Align the master tooth flat with the corresponding master tooth on the balancer shaft.

Figure 3-175. Outboard Retaining Ring Installation

12. See Figure 3-177. Install the COUNTERBALANCER

10. See Figure 3-175. Install out board retaining ring. Be cer- ALIGNMENT PIN (HD-45311). Use a new counterbal-

tain retaining ring is fully seated. ancer gear fastener and tighten to 50 Nm (37 ft-lbs) plus

Figure 3-177. Counterbalancer Gear Installation
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