Removal
1. Block motorcycle underneath frame so weight of motorcycle is off of rear wheel.
Note. A scissors style jack will allow you to raise or lower the motorcycle at different points throughout the procedure to provide both clearance and alignment during removal and installation.
2. Remove right side cover and maxi-fuse.
3. See Figure 2-69. Remove fasteners holding lower debris deflector (4) to rear fork. Remove debris deflector.
Figure 2-69. Rear axle: left side: 1. Belt guard; 2. Lower shock bolt; 3. Left side axle adjuster; 4. Debris deflector
4. If necessary, remove fasteners holding belt guard (1) to rear fork. Back lower shock bolt (2) out until belt guard is free and remove belt guard. Shock bolt retaining threads are integral to belt guard. Leave shock bolt in place to maintain alignment.
5. See Figure 2-70. Remove snap ring (2), axle nut (1) and adjuster (3) from right side of axle.
Figure 2-70. Rear axle (right side): 1. Axle nut; 2. Snap ring; 3. Right side spacer; 4. Right side axle adjuster
6. Relieve belt tension by rotating axle adjusters.
Caution! Support rear tire from underneath during removal. Failure to support rear tire may cause damage to the motorcycle as the axle is removed.
7. Tap axle towards left side until rear brake caliper is free.
8. See Figure 2-71. Slide rear caliper up off of brake disc towards front of motorcycle. Using a bungee cord, secure caliper to right side shock. Be sure rubber bumper stays with caliper.
Figure 2-71. Secured caliper with rubber bumper
9. Remove axle. Identify and set aside right and left spacers, right side axle adjuster, axle nut, and snap ring.
Caution! Polished aluminum wheels can be scratched or damaged when slid out of and into the rear fork. Exercise caution to avoid dragging wheel and sprocket surfaces against rear fork components.
10. Move wheel forward and slip belt off sprocket. Adjust height of the scissors jack to allow removing wheel assembly without damaging components.
Note. Note the height of the license plate bracket. Pulling the rear wheel can break off the reflector brackets.
11. Pull wheel and drive belt sprocket assembly from rear fork.
Note. Do not operate rear brake pedal with the rear wheel removed or the caliper piston may be forced out of piston bores. Reseating the piston requires disassembly of the caliper.
Disassembly
1. See Figure 2-72. Pull sprocket out of rubber compensator cushion (1) and compensator bowl (4) mounted to disc wheel.
Figure 2-72. Compensator cushion in compensator bowl: 1. Compensator cushion; 2. Compensator spacer; 3. PULLEY SIDE legend; 4. Compensator bowl; 5. Screws and helical spring lockwashers
2. Pull compensator spacer (2) and compensator cushion (1) from compensator bowl (4) mounted to disc wheel.
3. If tire replacement is necessary, remove tire and valve stem. See 2.26 Tires.
Note. If drive sprocket bearing surface is rough or if bearing is leaking grease, replace bearing in CLEANING AND INSPECTION procedures.
4. See Figure 2-68. If necessary, remove screws (4) and helical spring lockwashers (3) holding compensator bowl (2) to disc wheel (1). Remove compensator bowl (2).
5. If necessary, remove fasteners (15) that hold brake disc (16) to disc wheel (1) and remove brake disc (16).
Cleaning and inspection
1. Clean all parts in solvent and inspect all parts for damage or excessive wear.
Note. The wheels are aluminum and do not have a protective coating. Damage from harsh chemicals, acid based wheel cleaners, brake dust and lack of maintenance can occur. Use HARLEY-DAVIDSON WHEEL & TIRE CLEANER (Part No. 94658-98) to clean the wheels and tires and then use HARLEY GLOSS (Part No. 94627-98) to protect the aluminum wheel surfaces.
2. Inspect rear belt. See 1.15 Rear belt and sprockets.
3. Inspect sprocket bearing. If bearing surface is rough or if bearing was leaking grease, replace sprocket bearing as follows:
- a. Supporting hub inside compensator dogs, use a suitable drift to press bearing out of sprocket hub.
- b. Lubricate the bearing bore in the sprocket hub.
- c. Supporting hub from cosmetic side in such a manner as to not damage machined surface, use a suitable drift to press in a new bearing. To avoid damaging bearing, drift should press on outside race of bearing.
4. Inspect compensator cushion for missing chunks or excessive debris beyond normal wear marks. Replace if necessary.
5. Inspect brake disc. Replace disc if warped or badly scored. Measure disc thickness for excessive wear. Minimum acceptable thickness is stamped on side of disc.
6. If sealed wheel bearings must be serviced, see 2.24 Sealed wheel bearings.
Warning! Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Failure to install brake pads as a set could result in death or serious injury.
7. Inspect brake pads, calipers, and brake lines. Replace pads and service calipers and brake lines as required. See 1.10 Brake pads and discs.
Assembly
1. If necessary, mount tire, valve stem and balance wheel assembly as required. See 2.26 Tires.
2. Install brake disc, if removed, on valve stem side of wheel.
- a. Apply a drop of LOCTITE® 243 (blue) to the five bolts that hold on rear brake disc.
- b. Thread in and alternately tighten to 41-53 Nm (30-38 ft-lbs).
3. Install compensator bowl. Thread in screws and helical spring lockwashers. Tighten to 61-75 Nm (45-55 ft-lbs).
4. Verify that wheel and tire are true and balanced. See 2.25 Disc rim runout and 2.26 Tires.
5. After wheel is balanced, apply LOCTITE® ANTI-SEIZE LUBRICANT to entire surface of left side (compensator bowl) bearing race only.
6. See Figure 2-72. Lubricate compensator cushion (1) with a detergent spray like Windex™ and install compensator cushion. Be sure the PULLEY SIDE legend (3) is facing out.
7. Install the compensation spacer (2) with the grooved end in the cushion (1).
8. Insert sprocket dogs into compensator cushion to mate sprocket to rear wheel.
Installation
1. Install wheel into rear fork.
2. Slide drive belt over drive sprocket.
3. Slide brake calipers over front brake disc between brake pads. Lubricate rubber bumper with a detergent spray and slide slot in the caliper over brake anchor weldment on rear fork. Be sure rubber bumper is in place under weldment.
4. Coat axle with LOCTITE® ANTI-SEIZE LUBRICANT and install.
- a. From left side, carefully insert axle through rear fork, left side spacer, drive sprocket, compensator cushion, into wheel assembly.
- b. Continue sliding axle through wheel assembly hub sleeve, right side spacer, brake caliper, and left rear fork. Center right side spacer on wheel bearing to allow axle to pass through. Axle is fully installed when left side cam is tight against rear fork.
- c. Slip on right side axle adjuster. Right side axle adjuster will only fit in a manner that matches position of left side eccentric.
- d. Coat flange of axle nut with LOCTITE® ANTI-SEIZE LUBRICANT and thread on and finger tighten axle nut.
Warning! Whenever a wheel is installed, BEFORE moving motorcycle, you must pump brake fluid until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brakes will not be available to stop the motorcycle which could result in death or serious injury.
5. Pump brake pedal to move pistons out until they contact both brake pads. Verify piston location against pads.
6. Verify axle alignment and then check belt deflection. See 1.14 Rear belt deflection.
7. Use a wrench to rotate rear axle adjuster until drive belt deflection is within specifications.
Warning! Do not exceed 142 Nm (105 ft-lbs) when tightening the axle nut. Exceeding 142 Nm (105 ft-lbs) will cause the wheel bearings to seize during vehicle operation, which could result in death or serious injury.
8. Tighten axle nut to 129-142 Nm (95-105 ft-lbs).
9. Install snap ring.
10. If belt guard was removed, slide belt guard slots onto rubber grommets. Thread shock mount bolt into belt guard and tighten shock mount bolt to 41-68 Nm (30-50 ft-lbs).
11. Slide debris deflector slots on to its corresponding rubber grommet. Install debris deflector bolt and tighten bolt to 6-10 Nm (53-88 in-lbs).
12. Measure belt guard to drive sprocket clearance.
13. If clearance is less than 5 mm (0.197 in.), protect guard/ sprocket and adjust as required.
14. Replace maxi-fuse and right side cover.