PART NO. | SPECIALTY TOOL |
HD-45339 | Shift mechanism/detent retractor |
HD-45338 | Shift lever substitute |
HD-45301 | Transmission assembly retainer |
HD-45311 | Counterbalance alignment pin |
HD-45316 | Crankshaft assembly retainer |
HD-45306 | Crankshaft locking pin |
HD-45310 | Lower crankshaft alignment dowels |
Caution! Shafts in the Revolution transmission are closely toler-anced. Insertion of shafts must be done by hand. NEVER use a hammer or other tool to remove or install shafts. Transmission damage will result if force is used to insert shafts.
1. See Figure 3-129. Use SHIFT MECHANISM/DENTENT RETRACTOR (HD-45339) in reverse of disassembly to compress shifter gliding part and to compress shifting detent arm and spring. Using the nylon strap from the SHIFT MECHANISM/DETENT RETRACTOR (HD-45339), lower the shift drum in place and insert the shift drum shaft.
![](https://motoinstruction.ru/img/harley/2/111024.jpg)
Figure 3-129. Position shift drum
2. See Figure 3-130. Insert shifter fork shaft through engine case and slide shifter forks in position.
![](https://motoinstruction.ru/img/harley/2/111025.jpg)
Figure 3-130. Shifter fork shaft installation
3. See Figure 3-131. Shifter forks must be positioned as shown.
![](https://motoinstruction.ru/img/harley/2/111026.jpg)
Figure 3-131. Shifter fork orientation
4. See Figure 3-132. Install input shaft bearing retainer loosely in place.
![](https://motoinstruction.ru/img/harley/2/111027.jpg)
Figure 3-132. Input shaft bearing retainer
5. See Figure 3-133. A SMALL dab of RTV VRSC crankcase sealer around the output bearing locating pin hole will help to keep bearing from dropping during assembly. THIS IS ONLY DONE ON THE OUTPUT SHAFT FIRST GEAR BEARING.
![](https://motoinstruction.ru/img/harley/2/111028.jpg)
Figure 3-133. Locating pin hole
Caution! Attempting to assemble engine without the bearing locating pins in the correct position, will cause engine damage.
6. See Figure 3-134. and Figure 3-123. Carefully lower output shaft into case. Inspect to be certain that the locating pins (6) on the bearing outer race are in the case holes.
Note. Output shaft will turn freely when it is in the correct position.
![](https://motoinstruction.ru/img/harley/2/111029.jpg)
Figure 3-134. Output shaft
7. See Figure 3-135. Install two upper case fasteners in output shaft seal retainer.
![](https://motoinstruction.ru/img/harley/2/111030.jpg)
Figure 3-135. Output shaft seal retainer
Caution! Attempting to assemble engine without the bearing locating pins in the correct position, will cause engine damage.
8. See Figure 3-136. and Figure 3-123. Carefully lower input shaft into case. Inspect to be certain that the locating pins (6) on the bearing outer race are in the case holes and shifting forks are in the correct location.
![](https://motoinstruction.ru/img/harley/2/111031.jpg)
Figure 3-136. Input shaft
9. Use SHIFT LEVER SUBSTITUTE (HD-45338) to dry shift transmission while rotating input and output shaft. Make sure transmission shifts through all gears correctly.
10. See Figure 3-137. Install TRANSMISSION ASSEMBLY RETAINER (HD-45301) on input shaft as shown.
![](https://motoinstruction.ru/img/harley/2/111032.jpg)
Figure 3-137. Retain input shaft
11. See Figure 3-138. Install COUNTERBALANCER ALIGNMENT PIN (HD-45311). With the alignment mark in the 2 o’clock position, the case hole and the index hole in the counterbalancer will align.
![](https://motoinstruction.ru/img/harley/2/111033.jpg)
Figure 3-138. Counterbalancer alignment
Important note. Crankshaft bearings must be replaced every time the cases are split for service. If the cam drive is not being serviced, crankshaft bearings can be replaced without removing the cam drive chain.
12. Replace the crankshaft bearings at this time. See 3.16 Crankshaft bearing replacement.
13. See Figure 3-139. Lubricate crankshaft bearings, input and output shaft and counterbalancer bearings with Harley-Davidson Motorcycle Oil 20W50. Use Lubriplate No. 105 Assembly Grease (NAPA Part No. 765-2651) on bearing shells.
![](https://motoinstruction.ru/img/harley/2/111034.jpg)
Figure 3-139. Pre-assembly lubrication
14. See Figure 3-140. If engine was not atTDC, position the CRANKSHAFT ASSEMBLY RETAINER (HD-45316) to hold crankshaft thrust bearing half in place while attaining TDC.
![](https://motoinstruction.ru/img/harley/2/111035.jpg)
Figure 3-140. Retain Crankshaft thrust bearing
Caution! DO NOT ROTATE ENGINE CLOCKWISE. This is opposite the normal engine operation. Engine damage may result.
15. See Figure 3-141. Position the crankshaft assembly at TDC and insert the CRANKSHAFT LOCKING PIN (HD-45306).
![](https://motoinstruction.ru/img/harley/2/111036.jpg)
Figure 3-141. Crankshaft locking pin (HD-45306)
16. See Figure 3-142. Install LOWER CRANKCASE ALIGNMENT DOWELS (HD-45310).
![](https://motoinstruction.ru/img/harley/2/111037.jpg)
Figure 3-142. Lower crankcase alignment dowels (HD-45310)
Note. If dipstick has not been removed, do so at this time.
17. See Figure 3-132. Check that upper crankcase input bearing retainer is loosely in position.
18. See Figure 3-143. See Figure 3-144. Apply VRSC CRANKCASE SEALANT (Part No. 99650-02) to the lower case half.
![](https://motoinstruction.ru/img/harley/2/111038.jpg)
Figure 3-143. Apply sealant
Note. Lower case with the transmission gears in place is heavy. Get assistance when lifting lower case.
![](https://motoinstruction.ru/img/harley/2/111039.jpg)
Figure 3-144. Lower case sealant path:
Carefully clean case mating surfaces (gray shaded area).
Apply VRSC Crankcase Sealant (HD-99650-02) following black line.
Apply sealant only as indicated - DO NOT seal all mating surfaces.
![](https://motoinstruction.ru/img/harley/2/111040.jpg)
Figure 3-145. Case fastener sizes: 1. M10x150 (Part No. 968M); 2. M8x40 (Part No. 970M); 3. M8x90 (Part No. 1025M); 4. M8x120 (Part No.973M); 5. M8x160 (Part No. 972M); * Insert from upper case half
19. See Figure 3-146. Position lower case half over the LOWER CRANKCASE ALIGNMENT DOWELS (HD-45310).
![](https://motoinstruction.ru/img/harley/2/111041.jpg)
Figure 3-146. Lower case over alignment dowels
20. See Figure 3-147. When the counterbalancer gear and the primary crankshaft gear are close to engagement, remove the COUNTERBALANCER ALIGNMENT PIN (HD-45311). Hand position the counterbalancer gear so the timing marks are aligned exactly as shown.
![](https://motoinstruction.ru/img/harley/2/111042.jpg)
Figure 3-147. Lower case over alignment dowels
Caution! Confirm the correct alignment of the counterbalancer gear and the primary crankshaft gear timing marks. Engine damage will occur if the counterbalancer gear and the primary crankshaft gear are not correctly timed.
21. See Figure 3-145. Match and thread-in all 19 case fasteners.
22. See Figure 3-149. Torque in sequence all 19 case fasteners to 25 Nm (18.4 ft-lbs).
23. Dab a marker next to each torqued fastener as it is tightened.
Caution! Complete the tightening process on the main bearing bolts before tightening the rest of the case fasteners. Failure to do so will result in engine damage.
24. See Figure 3-149. Torque in sequence the four M10 x 150 main bearing bolts (1, 2, 3, 4) main bearing bolts in this sequence.
- a. Loosen each main bearing bolt (1, 2, 3, 4) one full turn (- 360°).
- b. See Figure 3-149. Torque in sequence each main bearing bolt (1, 2, 3, 4) to 15 Nm (11.1 ft-lbs).
- c. See Figure 3-148. Position the TORQUE ANGLE GAUGE (Snap-on Part No. TA360) per instruction sheet and tighten each bolt an additional quarter turn (+90°).
- d. Dab a marker next to each torqued main bearing bolt to identify which bolts have been tightened with the complete sequence.
![](https://motoinstruction.ru/img/harley/2/111043.jpg)
Figure 3-148. Torque angle gauge
![](https://motoinstruction.ru/img/harley/2/111044.jpg)
Figure 3-149. Engine case torque sequence: 1. M10x150 (Part No. 968M); 2. M10x150 (Part No.968M); 3. M10x150 (Part No. 968M); 4. M10X150 (Part No. 968M); 5. M8x120 (Part No. 973M); 6. M8x160 (Part No. 972M); 7. M8x90 (Part No. 1025M); 8. M8x90 (Part No. 1025M); 9. M8x120 (Part No. 973M); 10. M8x120 (Part No. 973M); 11. M8x40 (Part No. 970M); 12. M8x90 (Part No. 1025M); 13. M8x40 (Part No. 970M); 14. M8x40 (Part No. 970M); 15. M8x90 (Part No. 1025M); 16. M8x40 (Part No. 970M); 17. M8x40 (Part No. 970M); 18. M8x40 (Part No. 970M) (insert from upper case half); 19. M8x40 (Part No. 970M) (insert from upper case half)
Note. The notation for this torque sequence is written: 25 Nm - 360°, 15 Nm + 90°.
25. See Figure 3-150. Tighten the upper and lower input bearing retainer fasteners to 23 Nm (17 ft-lbs).
![](https://motoinstruction.ru/img/harley/2/111045.jpg)
Figure 3-150. Input bearing retainer
26. See Figure 3-151. Tighten the four output shaft bearing fasteners to 23 Nm (17 ft-lbs).
![](https://motoinstruction.ru/img/harley/2/111046.jpg)
Figure 3-151. Output shaft bearing retainer
27. See Figure 3-152. Place new oil pan gasket in position. Install oil pickup and fasteners. Tighten to 9.7 Nm (85 in-lbs).
![](https://motoinstruction.ru/img/harley/2/111047.jpg)
Figure 3-152. Oil pickup
28. See Figure 3-153. Install oil pan and fasteners. Tighten to 9.7 Nm (85 in-lbs).
![](https://motoinstruction.ru/img/harley/2/111048.jpg)
Figure 3-153. Oil pan
Table 3-30. Engine case fastener torque
FASTENER # | TORQUE | |
NM | FT-LBS | |
1 through 19 (in sequence) | 25 | 18.4 |
1, 2, 3, 4 (in sequence) | Backoff (-) 360° | |
1, 2, 3, 4 (in sequence) | 15 | 11 |
1, 2, 3, 4 (in sequence) | Tighten (+) 90° |