Disassembly 2nd Gear

Bearing Removal - 2nd Gear End ikwARNING

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.

1. See Figure 7-36. Remove retaining ring at 2nd gear crankcase bearing.

2. See Figure 7-37. Use puller to remove 2nd gear bearing. To protect the end of the shaft use END CAP (HD-34902), part of BIG-TWIN MAINSHAFT PRIMARY BEARING RACE REMOVER AND INSTALLER (HD-34902-B).

IMPORTANT NOTE

If no further disassembly of this end is needed go to step 3. If further disassembly of this end is needed go to step 4.

Bearing Installation - 2nd Gear End

1. See Figure 7-36. Remove retaining ring at 2nd gear crankcase bearing.

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Figure 7-38. 2nd Gear Bearing Alignment Pin

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Figure 7-36. 2nd Gear Bearing Retaining Ring

Figure 7-37. 2nd Gear Bearing 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.

Figure 7-38. 2nd Gear Bearing Alignment Pin

3. See Figure 7-38. Install new bearing with bearing alignment pin offset toward the gears. Use a pressing ring so installation force is on the inner race only.

Figure 7-39. 2nd Gear Bearing Retaining Ring

4. See Figure 7-39. Install retaining ring.

7. See Figure 7-42. Remove half moon keepers.

Figure 7-40.2nd and 5th Gear Removal

Figure 7-40.2nd and 5th Gear Removal

5. See Figure 7-40. Place a puller clamp behind 5th gear and press off 2nd and 5th gear. Support the input shaft when removing the gears.

NOTE

2nd gear is an interference fit and MUST be replaced when removed from the input shaft regardless of its condition.

Figure 7-41. Splined Thrust Washer

6. See Figure 7-41. Remove the splined thrust washer.

Figure 7-42. Half Moon Keepers

7. See Figure 7-42. Remove half moon keepers.

Figure 7-45. Half Moon Keepers

Figure 7-43. Shifting Fork Ring

8. See Figure 7-43. Remove shifting fork ring.

Figure 7-45. Half Moon Keepers

10. See Figure 7-45. Remove half moon keepers.

Figure 7-47. Split Cage Bearing

12. See Figure 7-47. Remove split cage bearing.

NOTE

See Figure 7-5. 1st gear and 3rd gear are part of the input shaft assembly and are not removable. Damage to 1st or 3rd gear requires replacement of the input shaft.

1. See Figure 7-48. Lubricate new split cage bearing and position on shaft. Install 4th gear and place half moon keepers in position.

Figure 7-50. Shift Fork Slider

3. See Figure 7-50. Install shift fork slider.

1. See Figure 7-48. Lubricate new split cage bearing and position on shaft. Install 4th gear and place half moon keepers in position.

Figure 7-48. 4th Gear and Keepers

Figure 7-50. Shift Fork Slider

3. See Figure 7-50. Install shift fork slider.

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Figure 7-52. Splined Thrust Washer

Figure 7-51. Half Moon Keepers

See Figure 7-51. Install half moon keepers.

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Figure 7-49. Splined Slider

See Figure 7-49. Insert splined slider with stepped side toward 4th gear.

Figure 7-51. Half Moon Keepers

See Figure 7-51. Install half moon keepers.

Figure 7-52. Splined Thrust Washer

5. See Figure 7-52. Install splined thrust washer, stepped side toward gears.

Figure 7-53. Bearing and 5th Gear

6. See Figure 7-53. Install lubricated new split cage bearing behind splined thrust washer. Install 5th gear over split cage bearing.

NOTE

2nd gear is an interference fit and MUST be replaced when removed from the input shaft, regardless of its condition.

7. See Figure 7-53. Install new 2nd gear. Use a pressing ring to clear the shaft. Press gear on shaft until it bottoms on the gearset.

8. To complete input shaft assembly -2nd gear end go to Bearing Installation - 2nd Gear End.

Figure 7-54. 2nd Gear

Figure 7-54. 2nd Gear

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