se left (sprocket) crankshaft roller bearing kit - Harley
Contents
1. resting the flywheel assembly on the fixture Slide the knurled locating pin down the slot in the tool to engage the crank pin hole Hand tighten the locating pin is02883 1 Hold down clamp 2 2 Locating pin Figure 7 Flywheel Fixture Part Number HD 44358 3 Slide the hold down clamp down the slot to engage the inboard side of the right flywheel half then hand tighten the knurled nut at the bottom to secure Repeat this step to secure the hold down clamp on the opposite side of the flywheel J05427 NOTE For proper clamping force hold down clamp must not be tilted Rotate hex on outboard stud until clamp is level 4 See Figure 7 Position the WEDGE ATTACHMENT HD 95637 46A on the inboard side of the thrust washer and turn the hex nuts an equal number of turns to draw the halves of the wedge together NOTICE Install wedge attachment only so far as necessary to ensure positive contact with bearing inner race Installing tool with more contact than necessary will result in damage to the flywheel 00500b 5 Obtain two 3 8 16 x 6 1 2 inch long bolts and flat washers Install the flat washers on the bolts Obtain the bridge forcing screw and hardened plug from the MAINSHAFT BEARING INNER RACE PULLER INSTALLER HD 34902B 6 Slide one bolt into the channel on each side of the bridge so that the flat washer is between the bridge and bolt head Thread the bolts into the wedge attachment an equal numb2. 4 See BOTTOM END OVERHAUL to assemble the engine bottom end 5 Follow the instructions under TOP END OVERHAUL in the service manual to assemble the engine top end 6 Install the engine into the motorcycle chassis Refer to INSTALLING ENGINE IN CHASSIS in the service manual 6 of 6
3. cMOTOR HARLEY DAVIDSON WY J05427 INSTRUCTIONS REV 2011 03 03 SE LEFT SPROCKET CRANKSHAFT ROLLER BEARING KIT GENERAL Kit Number 24004 03B Models For model fitment information see the Screamin Eagle Pro Racing Parts catalog English only Additional Parts Required NOTE You will need to obtain a 2003 or later service manual when performing this bearing installation on either a 1999 through 2002 or a 2003 or later Twin Cam model motorcycle You will need to obtain a 2007 or later service manual when performing this bearing installation on 2006 Twin Cam Dyna models or all other 2007 Twin Cam model motorcycles In addition to the above kit components this installation will require the separate purchase of an Oil Seal H D Part Number 12068 Installation on a 1999 through 2002 engine will also require the separate purchase of one of the following spacers e H D Part Number 24008 03 1 54 inch 39 mm long for FLT models e H D Part Number 24038 03 1 33 inch 34 mm long for Dyna models e H D Part Number 24039 03 1 43 inch 36 mm long for Softail models WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serio
4. e e See Figure 9 Thread the handle onto the pilot shaft 5 See Figure 10 Rotate the handle of the tool in a clockwise direction until the bearing inner race bottoms against the thrust washer 6 Remove the handle flat washer thrust bearing sleeve and pilot from the sprocket shaft 7 Follow the instructions in the applicable service manual for assembly of the remaining components crankcase assembly and installation in the chassis 2003 Style Flywheel Removal and Installation NOTE The bearing race and one thrust washer will be discarded from the kit see Figure 6 as the new flywheel comes with a race and thrust washer installed 1 Follow the instructions in the 2003 or later service manual to remove the existing bearing from the left crankcase half 2 Follow the instructions in the service manual for assembly of the new bearing 7 and lock ring 6 into the left half of the crankcase 3 Refer to CRANKCASE ASSEMBLY to assemble the crankcase using the new thrust washer 4 from the kit and a new Oil Seal H D Part Number 12068 available separately NOTE If installing the engine on a 1999 through 2002 vehicle also install a new spacer See the listing on Page 1 of these instructions for the correct spacer for your model motorcycle NOTICE Failure to install correct spacer will lead to insufficient clearance between the alternator rotor and stator which can result in a failed charging system 00501b
5. el in 2003 Style Crankcase or 1999 and Later Models with Screamin Eagle Stroker Flywheel in 2003 Style Crankcase THRUST WASHER AND BEARING REMOVAL AND INSTALLATION 2003 and Later Models with Stock Flywheel NOTE On the models listed above you will be removing the existing bearing race and thrust washer from the sprocket side of the crankshaft see Figure 6 and replacing them with a new race and thrust washer Follow the instructions in the appropriate service manual to remove the existing bearing from the left crankcase half then add the following procedures to remove and replace the existing bearing race and thrust washer onto the crankshaft 3 of 6 is02882 1 Flywheel assembly existing includes items 2 and 3 2 Thrust washer remove and replace 3 Bearing inner race remove and replace 4 Thrust washer 2 from kit 5 Bearing inner race from kit 6 Lock ring from kit 7 Straight roller bearing from kit 8 Crankcase left side shown save existing parts 9 Seal purchased separately 10 Spacer save existing part Figure 6 Bearing and Thrust Washer Installation 2003 and Later Models with Stock Flywheel Removal 1 Obtain FLYWHEEL SUPPORT FIXTURE HD 44358 see Figure 7 Install brass jaws or shop towels around the teeth of a vise to prevent tool damage Clamp the tool in the vise with the round hole topside 2 Insert the right side crankshaft end through the hole
6. er of turns 7 Sparingly apply graphite lubricant to the threads of the forcing screw to prolong service life and verify smooth operation Start the forcing screw into the center hole of the bridge NOTE Failure to use hardened plug may result in damage to forcing screw and or sprocket shaft 8 Place the cupped side of the hardened plug against the end of the sprocket shaft Thread the forcing screw into the bridge until the steel ball at the end of the screw makes firm contact with the hardened plug 4of6 is02884 Forcing screw 3 8 16 bolt Bridge Hardened plug Wedge attachment Bearing inner race is02885 Pilot shaft Handle Flat washer Thrust bearing Sleeve Inner race Thrust washer DO OT ON a Figure 9 Thrust Washer and Bearing Inner Race Installation NO Pw N Sprocket shaft Figure 8 Inner Race From Sprocket Removal IWIN NIN Be sure to follow manufacturer s instructions when using the Robinair Heat Gun or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00379a e Always keep hands away from tool tip area and heat shrink attachment e Be sure to turn the ON OFF switch to the OFF position after use 9 Using the Robinair Heat Gun HD 25070 uniformly heat the bearing inner race for about 30 seconds NOTE To facilitate removal without heat apply a ligh
7. he new thrust washer over the sprocket shaft 1 with the ink stamp facing outside and the chamfer on the ID toward the flywheel J05427 WARNING Be sure to follow manufacturer s instructions when using the Robinair Heat Gun or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00379a e Always keep hands away from tool tip area and heat shrink attachment e Be sure to turn the ON OFF switch to the OFF position after use 2 Place the new bearing inner race 3 on a bench top Using the Robinair Heat Gun HD 25070 uniformly heat the bearing inner race for about 60 seconds using a circular motion 3 Wearing suitable gloves to protect hands from burns place the heated bearing inner race over the sprocket shaft with number on bearing facing up NOTE To facilitate installation without heat apply a light penetrating oil to shaft and leading edge of bearing inner race NOTE Never use both heat and penetrating oil Use only one or the other Heat can cause the penetrating oil to ignite resulting in flames or fire is02916 Figure 2 Sprocket Shaft Bearing Installer Part Number HD 97225 55C 4 Obtain the SPROCKET SHAFT TAPERED ROLLER BEARING CONE INSTALLER HD 97225 55B See Figure 2 Assemble the tool as described below a See Figure 3 Sparingly apply graphite lubricant to the threads of the pilot
8. plicable 1999 2002 service manual to remove the existing tapered roller bearing from the crankshaft then perform the following steps 1 of 6 Please dispose of materials responsibly is02877 Flywheel and rod assembly Sprocket shaft on item 1 Bearing cone 2 Bearing outer race 2 Lock ring Shim bearing Crankcase left half shown Oil seal Spacer sprocket shaft Figure 1 Crankcase Removal 1999 2002 Models with Stock Flywheel in 2003 Style Crankcase or 1999 and later Models with Screamin Eagle Stroker Flywheel in 2003 Style Crankcase 1 2 3 4 5 6 7 8 9 THRUST WASHER AND BEARING RACE INSTALLATION 1999 2002 Models with Stock Flywheel in 2003 Style Crankcase 1999 and Later Models with Screamin Eagle Stroker Fly wheel in 2003 Style Crankcase NOTE On the models listed above you will be removing the bearing cone from the sprocket shaft and replacing it with a thrust washer and bearing race from the new Roller Bearing Kit Follow the instructions in the applicable service manual to remove the tapered roller bearing from the left crankcase half and the bearing cone from the crankshaft Perform the following steps to install the new thrust washer and roller bearing race to the crankshaft then follow the instructions in the 2003 or later service manual to install the new roller bearing to the crankcase half 1 See Figure 5 Obtain a thrust washer 2 from the kit Place t
9. shaft 1 to prolong service life and verify smooth operation b Thread the pilot onto the sprocket shaft 8 until con tact is made with the shoulder c Slide the sleeve 5 over the pilot until it contacts the bearing race 6 d Slide the thrust bearing 4 and large flat washer 3 over the pilot until contact is made with the sleeve e Thread the handle 2 onto the pilot shaft 5 See Figure 4 Rotate the handle of the tool in a clockwise direction until the bearing inner race bottoms against the thrust washer 2of6 is02879 Pilot shaft Handle Flat washer Thrust bearing Sleeve Inner race Thrust washer SN Oo PON gt is02881 Flywheel assembly existing Thrust washer 2 from kit Bearing inner race from kit Lock ring from kit Straight roller bearing from kit Crankcase left half shown new Seal purchased separately Spacer purchased separately See Table 1 Chamfer Or Oe aN Sprocket shaft Figure 3 Inner Race Installation is02880 Figure 4 Inner Race onto Sprocket Shaft Installation 6 Remove the handle flat washer thrust bearing sleeve and pilot from the sprocket shaft 7 See Figure 5 Follow instructions in the 2003 or later ser vice manual for assembly of the remaining components crankcase assembly and installation in the chassis J05427 Figure 5 Crankcase Installation 1999 2002 Models with Stock Flywhe
10. st washer from the sprocket shaft 17 Discard the bearing inner race and thrust washer Installation NOTE DO NOT re use the thrust washer removed from the sprocket shaft in the previous step 1 Place a new thrust washer 4 from the kit over the sprocket shaft with the ink stamp facing outside and the chamfer on the ID toward the flywheel 2 Place the new bearing inner race 5 on the bench top Using the Robinair Heat Gun HD 25070 uniformly heat the bearing inner race for about 60 seconds using a cir cular motion 3 Wearing suitable gloves to protect hands from burns place the heated bearing inner race over the sprocket shaft NOTE To facilitate installation without heat apply a light penetrating oil to shaft and leading edge of bearing inner race NOTE Never use both heat and penetrating oil Use only one or the other Heat can cause the penetrating oil to ignite resulting in flames or fire J05427 4 See Figure 2 Obtain the SPROCKET SHAFT TAPERED ROLLER BEARING CONE INSTALLER HD 97225 55C Assemble tool as described below a Thread the pilot onto the sprocket shaft until contact is made with the shoulder b Sparingly apply graphite lubricant to the threads of the pilot shaft to prolong service life and verify smooth operation c Slide the sleeve over the pilot until it contacts the bearing race d Slide the thrust bearing and large flat washer over the pilot until contact is made with the sleev
11. t penetrating oil to shaft and leading edge of bearing inner race NOTE Never use both heat and penetrating oil Use only one or the other Heat can cause the penetrating oil to ignite resulting in flames or fire 10 Turn the forcing screw until the thrust washer and bearing inner race moves approximately 1 8 inch 3 2 mm 11 Turn the hex nuts an equal number of turns to separate the halves of the WEDGE ATTACHMENT J05427 is02886 12 Figure 10 Inner Race onto Sprocket Installation After bottoming the thrust washer on the shaft reposition the WEDGE ATTACHMENT HD 95637 46A on the inboard side of the bearing inner race Turn the hex nuts an equal number of turns to draw the halves of the wedge together 5 of 6 NOTICE Install wedge attachment only so far as necessary to ensure positive contact with bearing inner race Installing tool with more contact than necessary will result in damage to the flywheel 00500b 13 Verify that the tool assembly is square so that the bearing inner race is not cocked during removal 14 See Figure 8 Using the Robinair Heat Gun HD 25070 uniformly heat the bearing inner race for about 30 seconds using a circular motion NOTE To facilitate removal without heat apply a light penetrating oil to shaft and leading edge of bearing inner race 15 Turn the forcing screw until the bearing inner race is pulled free of the sprocket shaft 16 Remove the thru
12. us injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer J05427 Kit Contents Table 1 Kit Contents Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Description Quantity Part Number Bearing flywheel left side 24605 07 Ring retaining 35114 02 Washer thrust 2 service version 8972 Race inner Not Sold Separ ately INSTALLATION 1 Remove the engine from the motorcycle chassis Refer to REMOVING ENGINE FROM CHASSIS in the applicable service manual 2 Follow the instructions under TOP END OVERHAUL in the service manual to disassemble the engine top end 3 See BOTTOM END OVERHAUL to disassemble the engine bottom end 4 Refer to CRANKCASE DISASSEMBLY to disassemble the crankcase 5 See LEFT CRANKCASE HALF to remove the crankshaft from the left crankcase half 6 For 2003 and later models with stock flywheel proceed to e Thrust Washer and Bearing Race Removal Installation 2003 and Later Models with Stock Flywheel or e Flywheel Removal Installation Models with 2003 Style Crankcase For 1999 2002 models with stock flywheel and for 1999 and later models with Screamin Eagle Stroker flywheel and 2003 Style Crankcase see Figure 1 Follow the instruc tions in the ap
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