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, which could cause death or serious injury, remove main fuse before proceeding.
Preparation
1. Remove main fuse.
2. Shift transmission into neutral.
XL models
1. Remove rear muffler and rear exhaust pipe. See 4.13 EXHAUST SYSTEM: XL MODELS.
2. See Figure 5-102. Remove screw (6), washer (5) and exhaust pipe clamp bracket (4). Remove two screws (2, 3) and remove sprocket cover (1).
![](https://motoinstruction.ru/img/harley/12/118233.jpg)
Figure 5-102. Sprocket cover: XL models: 1. Sprocket cover; 2. Screw; 3. Screw; 4. Exhaust pipe clamp bracket; 5. Washer; 6. Screw
3. Remove belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR.
4. Remove rear drive belt from transmission sprocket. Pull belt back out of the way. Do not bend belt too tightly or twist belt. See 5.6 DRIVE BELT.
5. See Figure 5-103. Remove screw and washer (6) from exhaust interconnect bracket.
![](https://motoinstruction.ru/img/harley/12/118234.jpg)
Figure 5-103. Transmission sprocket assembly: all models: 1. Main drive gear shaft; 2. Transmission sprocket; 3. Transmission sprocket nut; 4. Lockplate; 5. Screw (2); 6. Screw and washer
XR 1200X
1. Remove exhaust system. See 4.14 EXHAUST SYSTEM: XR 1200X.
2. Remove three screws securing sprocket cover to engine crankcase. Remove sprocket cover.
3. Remove belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR.
4. Remove the rear brake master cylinder assembly:
- a. Remove two screws securing rear brake master cylinder assembly, rider footrest and mounting bracket to vehicle's frame.
- b. Carefully pull assembly back out of the way. Secure to frame with cable strap or bungee cord.
- c. Do not kink or bend metal portion of brake line.
5. Remove rear drive belt from transmission sprocket. Pull belt back out of the way. Do not bend belt too tightly or twist belt. See 5.6 DRIVE BELT.
All models
1. See Figure 5-103. Remove two screws (5) and sprocket lockplate (4).
Notes:
- See Figure 5-105. On XR 1200X and XL models without passenger footrests, install FINAL DRIVE SPROCKET HOLDING TOOL REACTION ADAPTER (Part No. HD-46282-1A) into bottom footrest bracket hole in frame. Place handle of tool underneath adapter.
- If the engine is mounted in the ENGINE CRADLE (Part No. HD-42310-45), the rear crankcase support serves as a tool stop for the sprocket holding tool.
![](https://motoinstruction.ru/img/harley/12/118236.jpg)
Figure 5-105. Sprocket holding tool and adapter (installation XR 1200X): 1. Transmission sprocket holding tool; 2. Sprocket holding tool adapter
2. See Figure 5-104. Install the FINAL DRIVE SPROCKET HOLDING TOOL (Part No. HD-46282-A) (1). Hold the sprocket nut with MAINSHAFT LOCKNUT WRENCH (Part No. HD-46288) (2). Use a breaker bar (3) to loosen the nut. Place handle of sprocket holding tool under bottom of footrest bracket. Turn nut clockwise to remove it.
![](https://motoinstruction.ru/img/harley/12/118235.jpg)
Figure 5-104. Removing transmission locknut: 1. Transmission sprocket holding tool; 2. Mainshaft locknut wrench; 3. Breaker bar
Installation
PART NUMBER | TOOL NAME |
HD-46282 | TRANSMISSION SPROCKET HOLDING TOOL |
HD-46282-1A | SPROCKET HOLDING TOOL ADAPTER |
HD-46288 | MAINSHAFT LOCKNUT WRENCH |
FASTENER | TORQUE VALUE | |
Transmission sprocket nut | 50 ft·lbs | 68 Nm |
Transmission sprocket lockplate fastener | 90-120 in·lbs | 10.3-13.6 Nm |
Muffler interconnect bracket mounting screw: XR 1200X | 30-33 ft·lbs | 40.7-44.8 Nm |
Exhaust pipe clamp bracket fastener: XR 1200X | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Footrest mount fastener | 45-50 ft·lbs | 61-68 Nm |
Sprocket cover, rear screw | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Preparation
1. See Figure 5-103. Install transmission sprocket (2) onto main drive gear shaft (1).
Note. See Figure 5-105. On XR 1200X and XL models without passenger footrests, screw SPROCKET HOLDING TOOL ADAPTER (Part No. HD-46282-1A) into top footrest bracket hole in frame. Place handle of tool on top of adapter.
2. Shift transmission into neutral. Apply LOCTITE 262 HIGH STRENGTH THREADLOCKER AND SEALANT (red) to the left-hand threads of transmission sprocket nut (3). Apply a thin film of SCREAMIN' EAGLE ASSEMBLY LUBE to the back face of the sprocket nut. Turn the nut counterclockwise to install it onto main drive gear shaft.
- a. See Figure 5-106. Use TRANSMISSION SPROCKET HOLDING TOOL (Part No. HD-46282) (1), MAIN-SHAFT LOCKNUT WRENCH (Part No. HD-46288) (2), and a torque wrench (3). Place handle of sprocket holding tool on top of footrest bracket. Tighten nut to 50 ft·lbs (68 Nm) initial torque, ONLY.
- b. See Figure 5-107. Scribe a line on the transmission sprocket nut and continue the line on the transmission sprocket as shown.
- c. Tighten the transmission sprocket nut an additional 30-40 degrees.
- d. See Figure 5-103. Install lockplate (4) over nut (3) so that two of lockplate's four drilled holes (diagonally opposite) align with sprocket's (2) two tapped holes.
![](https://motoinstruction.ru/img/harley/12/118237.jpg)
Figure 5-106. Tightening transmission locknut: all models: 1. Transmission sprocket holding tool; 2. Mainshaft locknut wrench; 3. Torque wrench
![](https://motoinstruction.ru/img/harley/12/118238.jpg)
Figure 5-107. Transmission sprocket nut final tightening procedure: 1. Transmission sprocket; 2. Sprocket nut; 3. Line scribed on nut and sprocket
Note. The lockplate has can be turned to either side to align the screw holes. If the screw holes cannot be properly aligned, tighten the nut slightly until the holes align. Do not exceed 45 degrees. Never LOOSEN nut to align the screw holes.
Note. Always install BOTH screws to secure the lockplate.
3. Install socket head screws (5) through two of the four holes in lockplate, then into two corresponding tapped holes in sprocket. Tighten to 90-120 in·lbs (10.3-13.6 Nm).
4. XR 1200X and XL Models without Passenger Footrests: Remove SPROCKET HOLDING TOOL ADAPTER (Part No. HD-46282-1A).
XL 1200X
1. See Figure 5-103. Install screw and washer (6) to secure muffler interconnect bracket to engine crankcase. Tighten to 30-33 ft·lbs (40.7-44.8 Nm).
2. Install rear drive belt onto transmission sprocket. See 5.6 DRIVE BELT.
3. Adjust rear belt deflection and rear wheel alignment. See 1.24 WHEEL ALIGNMENT.
4. Install belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR.
5. See Figure 5-102. Install sprocket cover (1). Secure with two screws (2, 3). Note that long screw goes in top hole, short screw in bottom hole. Do not tighten screws at this time.
6. Install exhaust pipe clamp bracket (4), washer (5) and screw (6). Tighten to 30-33 ft·lbs (40.7-44.8 Nm). Now tighten screws (2, 3) to 80-120 in·lbs (9.0-13.6 Nm).
7. Install rear exhaust pipe and rear muffler. See 4.13 EXHAUST SYSTEM: XL MODELS.
XR 1200X
1. Install rear drive belt onto transmission sprocket. See 5.6 DRIVE BELT.
2. Adjust rear belt deflection and rear wheel alignment. See 1.24 WHEEL ALIGNMENT.
3. Attach rear brake master cylinder, rider footrest and mounting bracket assembly to frame with two screws. Tighten to 45-50 ft·lbs (61-68 Nm).
4. Install belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR.
5. Install sprocket cover.
- a. Install longer screw in top hole.
- b. Install shorter one in bottom hole.
- c. Install larger diameter fastener in rear hole.
- d. Tighten rear(largerdia.)fastenerto30-33 ft·lbs(40.7-44.8 Nm).
- e. Tighten forward and lower (smaller) screws to 80-120 in·lbs (9.0-13.6 Nm).
6. Install exhaust system. See 4.14 EXHAUST SYSTEM: XR 1200X.
All models
Install main fuse.