Harley Davidson Touring 2004 Service Manual sm appd
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1WARNING1WARNING
CAUTION
Mainshaft
Plug
9411
JAPANESE MAINSHAFT/COUNTERSHAFT D.1
NOTE
Check the eight digit number stamped on the transmission
case just above the side door. If the third digit is “9,” then the
transmission was built for Japan only. If the digit is “0,” then it
was built for all countries except Japan. See the instructions
which follow if servicing a Japanese transmission. For all
other transmissions, see Section 7.6 MAINSHAFT/COUN-
TERSHAFT.
DISASSEMBLY
NOTES
●
Perform all steps if completely overhauling the transmission assembly.
●
Perform steps 1-11 and 17-18 if replacing only
tershaft or one or more countershaft gears.
Perform steps 1-5 and 12-18 if replacing only
●
shaft or one or more mainshaft gears.
the coun-
the main-
Figure D-2. Press Out Countershaft
Perform steps 1-6, 12, and 17-18 if replacing only
●
side door bearings.
1. Position the side door assembly on a bench with the
shafts pointing straight up, the mainshaft on the left hand
side. The mainshaft is the longer of the two shafts. See
Figure D-3.
2. Slide off the mainshaft 2nd gear (spur).
NOTE
To facilitate reassembly, label each gear as it is removed.
See Figure D-1.
3. Obtain the TRANSMISSION SHAFT RETAINING RING
PLIERS, Part No. J-5586.
the
9412
Always wear proper eye protection when removing 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. Locate retaining ring just above the mainshaft 3rd gear
(spur). Move the retaining ring up approximately 3/8 inch
(9.5 mm) towards the free end of the shaft. Turn side
door assembly upside down and verify that mainshaft
3rd gear is still partially engaged with countershaft 3rd
gear.
Failure to move the retaining ring on the mainshaft can
cause countershaft 1st gear to contact mainshaft 3rd
gear when the countershaft is pressed out. On the other
hand, if the retaining ring is moved too far, loss of
engagement between mainshaft 3rd gear and countershaft 3rd gear can result in hard contact between these
two gears. Any hard contact can result in gear tooth
damage.
5. With the outboard side up, rest side door on parallel
blocks under ram of arbor press. Be sure that assembly
is flat and does not rest on dowel on inboard side.
Figure D-1. Note Gear Location During Disassembly
6. Center countershaft under ram. Install mainshaft plug
into hole at end of countershaft. Slowly apply pressure
until countershaft is free. See Figure D-2. Remove main-
shaft plug.
Appendix D D-1
HOME
9413
1 10
11
3
2
4
126
4
3
6
5
4
13
3
4
3
7
146
3
4
4
3
68
9
15
16
1. Mainshaft
2. 2nd Gear
3. Retaining Ring
4. Thrust Washer
5. 3rd Gear
6. Split Cage Bearing
7. 1st Gear
8. 4th Gear
7. Slide blue spacer and countershaft 4th gear (helical) off
threaded end of countershaft.
D-2 Appendix D
9. Gold Spacer
10. Countershaft
11. 5th Gear
12. 2nd Gear
13. 3rd Gear
14. 1st Gear
15. 4th Gear
16. Blue Spacer
Figure D-3. Fully Assembled Side Door
8. Secure countershaft in a vise with the threaded end top-
side. Be sure to install a pair of aluminum or brass jaw
inserts in vise to avoid parts damage. See Figure D-4.
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