2006 road king main shaft puller

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HARLEY DAVIDSON ROAD KING SOLO BUCKET AND PASSENGER PILLION INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 10-02-2011

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Installation SOLO SADDLE ONLY 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider solo seat. 2000 and later models . Remove the retainer washer from the stud plate and replace with two black retainer washers (2). Be careful not to allow stud plate to fall through the fender. 3. Road King standard models . Install stock solo seat mount bracket using two stock screws saved in Step 2. Road King Classic Custom models . Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. Install seat by sliding front of seat into seat holder bracket. Pull up on the nose of the seat to verify that the seat is securely installed. After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 5. 1999 and later models . Install 1/4 in. star washers (6), spacers (4) and acorn nuts (3) onto rear mount studs. Torque to 72 in-lbs (8.13 Nm). 1998 and earlier models . Install 5/16 in. star washers (5) and 5/16-18 x 3/4 in. buttonhead screws (1) into stock mount nuts. Torque to 17 ft-lbs (23 Nm). SOLOAND PILLION 1. Remove stock seat and grabstrap according to applicable Service Manual instructions. Retain all hardware for later use. 2. Road King standard models . Remove and save the stock screws and seat mount bracket at the back of the rider seat. 3. Road King standard models. Install stock seat mount bracket onto new solo seat using two screws saved in Step 2. Road King Classic Custom models. Install solo seat mount bracket onto back of solo seat using bracket and screws included in Mount Kit Number 52903-01. 4. 1999 and later Road King standard models . Secure the rear mount bracket with stock mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). 1998 and earlier Road King standard models . Install solo seat by sliding front of seat into holder bracket on bike. Secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm). Road King Classic Custom models . Mount Kit Number 52903-01 is required for installation. Install solo seat (7) by sliding front of seat into holder bracket on bike. • 1999 and later models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom nuts (10) and two 1/4 in. star washers (6). Torque to 72 in-lbs (8.13 Nm). • 1998 and earlier models . Using Mount Kit Number 52903-01, secure the rear mount bracket with the two mushroom screws (11) and two 5/16 in. star washers (5). Torque to 17 ft-lbs (23 Nm)

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HARLEY-DAVIDSON 5 Speed Transmissions 1984 – 1999 EVO / 5 Speed & 1999 – 2006 Twin Cam Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-11-2010

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Remove Original Parts From Vehicle. 2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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BMW F650 CS Front belt wheel not correctly secured

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Filed Under (BMW) by admin on 23-11-2010

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2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure 2.3 Wear check gearbox main shaft- It is extremely important that the techni- cian always check that the dimensions of the gearbox main shaft splines are to specification before proceeding with the installation of a new front belt wheel. This note only applies to motorcycles with accumulated mileage, not to new motorcycles from the crate. If the visual inspection was satisfactory and the main shaft was not replaced for visual damage, a main shaft wear check will be necessary. This check requires the use of BMW Special Tool # 23 4 571 . The adapters are designed for micrometer gauges with stud diameters from 6.35 mm to 6.6 mm. Do not use cellulose-lacquer thinners to clean the adapters as there is a risk of damaging the measuring instruments. Make sure that the micrometer gauges and the adapters are perfectly clean

HARLEY DAVIDSON WHEEL BEARING REMOVAL AND INSTALLATION TOOL

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Filed Under (Harley Davidson) by admin on 19-02-2011

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BEARING REMOVAL 1. Place the wheel vertically in a vise and protect the rim from being marred. NOTE See Figure 1 for the tool lubrication locations before using. 2. Assemble the remover tool. a. Install wheel bearing puller (1), (2) or (16) depending on the bearing I.D. See the service parts table for the size reference. Install the wheel bearing puller into the bearing by hand or use a rubber mallet ( not a hard-faced hammer) to push through the bearing I.D. Stop pushing on the bearing puller as soon as it has cleared the inside of the bearing race. There will be a slight click. b. Place main body puller (3) over bearing puller with the fingers of main body puller facing the wheel. Lightly oil all threads. c. Place the large brass washer (10) and nut (13) onto the puller and hand-tighten the nut until it stops at the top face of the bridge. 3. Remove the front wheel bearings. a. Apply a small amount of oil to the taper at the hex end of the expander dowel. Insert the expander dowel (7) through the other side of wheel bearings, and through the bearing puller. b. Install the washer (15 and nut (14) to the expander dowel and torque to 100 in-lbs (11.3 Nm) with a 11/16 inch wrench or socket while holding the other side of the expander dowel by reaching the opposite side of the wheel with a 3/8 inch hex key. c. Align the main body puller support fingers centered over the bearing to be removed. If main body puller will be directly on a finished chrome surface, protect the surface area. d. If resistance is felt with a torque wrench set at 40 ft- lbs (54.2 Nm) of torque, you will need to apply heat to the hub area surrounding the bearing. Prior to applying heat, place 2 to 3 temperature stickers (P/N 94146-10) around the circumference of the hub. Apply indirect heat using a heat gun. Do not exceed 210°F. With a 1-1/8 inch socket and torque wrench, turn the nut (13) until the bearing is pulled free from the wheel hub. e. Using a 3/8 in. hex key on an extension and torque wrench set on the expander dowel (7) and a 1-1/8 inch wrench. Turn the nut (13) until the bearing is free of the wheel hub. 4. Remove the wheel bearing spacer from the I.D. of the wheel hub. 5. Repeat steps 1 through 4 for the opposite bearing. NOTE Remove rear wheel belt sprocket before removing the bearings. 6. Rear wheel bearing removal is the same as steps 1 through 4 by using the correct size wheel bearing puller

Harley Davidson FL series Electra Glide, Ultra Classic, Road King, Road Glide Left and Right Mounting Plate Installation Installation Manual

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Filed Under (Harley Davidson) by admin on 25-02-2012

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Remove existing control arm end cap and grind the outside flush. See picture below for reference. The swing arm will drop if both sides are removed at the same time. To ease installation, complete one side before starting on the other. Note: there is a left and right. Left and right end caps shown. 2. Install mounting plate assembly 10002351 on top of the end cap using 7/16″ hex head bolt and lock washer in the bottom hole. Use the 7/16″ counter sink bolt in the top hole. Make sure the end cap is seated properly. The end cap notch should fit into the recess on the frame. The pivot arm assembly is shipped on mounting plate assembly; you may remove the pivot arm to make installation easier. 3. Snug up the bolts evenly, make sure the end caps are not crooked in relation to the frame. Tighten both bolts to 25 ft lbs. (Further tightening will be required after the toe in is set). 4. If you removed the left hand pivot arm assembly, remount it now, 10002575-A (pg 20) with seal, bearings (2), washer, nut, cotter pin and dust cover. 5. Repeat for right hand side. 5 Toe In Adjustment Adjustment made with the mounting plates, bolts, pivot arms, and hubs (without wheels and tires) in place

HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

2000 Harley-Davidson FLHRCI Road King Classic

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Filed Under (Harley Davidson) by admin on 03-11-2010

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the Road King® Classic is a motorcycle with enough traditional styling to drop jaws throughout the continent. The Road King® Classic boasts laced wheels, fat white-walls and gorgeous leather saddlebags with hard inserts so they keep their shape across the long miles. Slightly narrower new handlebars provide improved ergonomics. Fender tips, tank and seat valance all boast a metal emblem. The model is available with a fuel-injected, chrome-and-black Harley- Davidson® Twin Cam 88 engine. Specifications: Engine Type: 1449 cc, 4-Stroke, Air Cooled, V-Twin Engine Bore and Stroke: 95.3 mm x 101.6 mm Valves 2 valves/cylinder Claimed Horsepower: 67 hp (50 kW) @ 5200 rpm Maximum Torque: 110 Nm (81.1 ft. lbs) @ 3100 rpm Transmission type: 5 speed Final Drive: Belt Tire – Front: 130/90-16 Tire – Rear: 130/90-16 Brakes – Front: dual 292 mm discs with 4-piston calipers Brakes – Rear: single 292 mm disc with 4-piston calipers

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