Fastener torque values The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE Notes Axle, rear, nut 95-105 ft·lbs 129-142 Nm 5.6 DRIVE BELT , Drive Belt: XL Models Axle, rear, nut 95-105 ft·lbs 129-142 Nm 5.6 DRIVE BELT ,...
Specifications of transmission Table 5-1. Sprocket teeth DRIVE ITEM NUMBER OF TEETH XL 883 MODELS XL 1200 MODELS XR1200X U.S. WORLD U.S. WORLD U.S./WORLD Primary Engine 34 34 38 38 34 Clutch 57 57 57 57 57 Final Transmission 29 29 29 30 28 Rear wheel 68 68 68 68 68 Table 5-2....
Primary cover — removal and installation Removal Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. 1. Disconnect the negative (-) battery cable from the engine stud on the back...
Primary drive and clutch: XR 1200X models Removal PART NUMBER TOOL NAME HD-38362 SPORTSTER 5-SPEED SPROCKET LOCKING LINK HD-46283 PRIMARY DRIVE LOCKING TOOL Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-)...
Drive belt — removal and installation Drive belt handling See Figure 5-36. Do not exceed 5 in (127 mm) forward bend (1). Do not exceed 10 in (254 mm) reverse bend (2). Do not twist (3). Do not crimp, pinch or kink (4). Do not pry (5). Figure 5-36. Drive belt handling Drive belt: XL...
Transmission power flow See Figure 5-44. The transmission is a five-speed constantmesh type housed in an extension of the crankcase. The transmission permits the rider to vary the ratio of engine speed-to-rear driving wheel speed in order to meet the varying conditions of...
Case disassembly for transmission removal The rear compartment of the left and right crankcase halves form the transmission case. Servicing of transmission components requires removing the engine and disassembling (splitting) the crankcase. Engine removal and disassembly PART NUMBER TOOL...
Transmission removal and disassembly Transmission removal from left crankcase PART NUMBER TOOL NAME B-43895-1 REMOVER B-43985 TRANSMISSION REMOVAL AND INSTALLATION TOOL Note. See Figure 5-55. Shifter design allows for one common part number for both countershaft shifter forks (4, 5)....
Transmission assembly Mainshaft assembly PART NUMBER TOOL NAME J-5586-A RETAINING RING PLIERS Warning! Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause...
Main drive gear and bearing — removal, installation, disassembly and assembly Note. See Figure 5-64. Main drive gear (2) removal requires replacement of the main drive gear bearing (7 or 14). Gear removal procedure destroys bearing's inner race. Figure 5-64. Main drive gear and bearing assembly: 1. Needle bearing (2); 2. Main...
Transmission right case bearings — removal and installation Removal PART NUMBER TOOL NAME HD-95760-69A BUSHING AND BEARING PULLER HD-95765-69A 1/2 INCH COLLET Split crankcases. See 5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL . Countershaft needle bearing See Figure 5-86. From inside transmission case use a...
Transmission left case bearings — removal and installation Removal PART NUMBER TOOL NAME PR-36 SNAP-ON SNAP RING PLIERS Mainshaft and countershaft bearings 1. Split crankcases. See 5.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL . 2. Disassemble transmission. See 5.9 TRANSMISSION REMOVAL AND DISASSEMBLY . a....
Transmission installation Before reinstalling transmission and reassembling crankcase halves, perform any necessary engine overhaul procedures. See 3.9 BOTTOM END SERVICE and 3.8 TOP END SERVICE . Installation PART NUMBER TOOL NAME B-43985 TRANSMISSION REMOVAL AND...
Transmission sprocket — removal and installation Removal PART NUMBER TOOL NAME HD-42310-45 ENGINE CRADLE HD-46282-1A FINAL DRIVE SPROCKET HOLDING TOOL REACTION ADAPTER HD-46282-A FINAL DRIVE SPROCKET HOLDING TOOL HD-46288 MAINSHAFT LOCKNUT WRENCH Warning! To prevent accidental vehicle start-up,...