TIMKEN BEARING CONVERSION TOOL - Harley
Contents
1. 1 Bottom locator plate installed 2 Socket head screws 4 Figure 2 Bottom Locator Plate Bearing sleeve Press plate Dowel pin Pensa Press plug Figure 3 Bearing Insert and Press Plate 7 Apply a small amount of lube to the four socket head cap screws 2 and thread the screws by hand letting the locater plate align itself to the case Tighten screws in a criss cross pattern to 40 in Ibs 4 5 Nm 8 Place the bearing sleeve 1 on the underside of the press plate 2 while aligning the press plates 1 8 inch dowel pin 3 with the 1 8 inch hole in the bearing sleeve flange 9 Insert the press plug 4 through the center hole in the press plate 2 and through the center of the sleeve 10 See Figure 4 Holding the press plate assembly and sleeve together place the assembly over the bearing bore of left case with the sleeve aligned and centered in the case bore The 1 2 inch and 3 8 inch dowel pins should be aligned and through the bottom locater plate Align this assembly under the press J04672 NOTES The only time you should stop the pressing operation is if the sleeve did not start in the bore straight The tool is designed so that it only allows the sleeve to be installed straight into the case bore One major reason for the sleeve not starting straight into the bore is the press ram is not within 0 010 inch to the press plate Shim the press as needed If for any reason you need to re2. collar 1 8 inch ID 1264 6 Screw 10 24 x 1 1 2 inch SHCS 4 1234 7 Drill stop collar 3 16 inch ID 1267 8 Drill bit 3 16 inch HSS jobber length 2 1714 9 Screw 3 8 16 x 2 1 2 inch SHCS 1128 10 Drill bit 25 HSS jobber length 1713 11 Roll tap 8 32 2288 12 Tool base 2246 1 13 Tool case 2120 14 Tap guide tool 959 4 15 Drill bit collar 0 1495 ID 8 32 1292 J04672 10 of 10
3. must be large enough to allow nut to rest flat against spacer sleeve Clamp welded sprocket shaft nut in vise so that the dummy sprocket shaft points straight up With the tapered side up slide bearing cone over end of dummy sprocket shaft Using the thumbs of both hands lightly press on bearing cone until it bottoms against shoulder With the outboard side up carefully place left crankcase half over dummy shaft so that it rests flat on installed bearing cone Slide new spacer ring over dummy shaft until it con tacts bearing cone Place new bearing cone over dummy shaft with the tapered side down Install spacer sleeve flat washer and dummy compen sating sprocket shaft nut Tighten nut to 150 165 ft lbs 203 224 Nm is05664 Figure 15 Check Flywheel End Play 6 of 10 Using dial indicator a See Figure 15 Mount a dial indicator on the case half Set the indicator contact point on the end of the dummy sprocket shaft b Standing on a stool for leverage if necessary firmly push down on the case as far as it will go while rotating it back and forth c Holding the case down zero the dial indicator gauge d Firmly pull up on the case as far as it will go while rotating it back and forth Stand on a stool for leverage if necessary e Holding the case up note the reading of the dial indicator Repeat procedure to verify the reading f If the end play falls between 0 003 0 007 in 0 07
4. to start low speed drilling for the oil feed hole Allow the drill bit to go through the top guide hole in the press plate Use tapping fluid as needed to keep the drill bit from clogging Drill down into the case until the stop collar stops at the press plate 3 of 10 is05596 i Figure 8 Drilling Oil Drain Hole is05597 bit from clogging Drill down into the case until the stop collar stops at the press plate 17 See Figure 21 Table 3 and Figure 9 Using drill bit 10 assembly start low speed drilling through the 2 o clock guide hole for the flange mounting screws Use tap lubri cant as needed to keep the drill bit from clogging up Drill down into the case until the stop collar stops at the press plate Repeat for the remaining 5 guided drill holes Remove all chips when drilling is completed 7 is05598 o o Figure 9 Drilling Mounting Screw Holes 16 See Figure 21 Table 3 and Figure 8 Use drill bit 4 assembly to start low speed drilling for the oil drain hole Allow the drill to go through the bottom guide hole into the press plate Use tapping fluid as needed to keep the drill J04672 Figure 10 Tapping Lock Screw Holes 18 See Figure 21 Table 3 and Figure 10 Install the tap 11 into your tap handle Hold tap guide 14 with the laser marked side up in your hand Insert the tap through the hole of the tap guide plate 14 with the tap protruding about 1 8
5. 6 0 178 mm using a dummy shaft proceed to step 5 If end play must be adjusted change spacer according to step 4 NOTE For testing purposes only dummy shaft end play specification is not equal to final end play specification of 0 001 0 005 inch 0 025 0 127 mm 5 If end play is not within specification remove dummy compensating sprocket shaft nut flat washer spacer sleeve bearing cone and spacer ring Measure spacer ring with dial vernier caliper and see Table 3 Replace spacer with one of those listed using a thinner spacer ring for less end play or a thicker spacer ring for more end play Return to step 3f to repeat end play check Remove dummy compensating sprocket shaft nut flat washer and spacer sleeve Carefully remove all Timken bearing parts from dummy sprocket shaft See Figure 16 Place base of FLYWHEEL REBUILDING JIG 7 part number HD 44358 in vise Insert crankshaft end of flywheel assembly into fixture J04672 isO5665 Pilot shaft Handle Flat washer Nice bearing Sleeve Bearing cone Flywheel rebuilding jig 1 2 3 4 5 6 7 Figure 16 Sprocket Shaft Timken Bearing Cone Installer 8 Place new bearing cone 6 over sprocket shaft with the tapered side up Obtain the SPROCKET SHAFT TIMKEN BEARING CONE INSTALLER part number HD 97225 55B a Thread pilot shaft 1 onto sprocket shaft until contact is made with shoulder b Sparingly apply graph
6. cMOTOR HARLEY DAVIDSON WY J04672 INSTRUCTIONS REV 2008 07 23 TIMKEN BEARING CONVERSION TOOL GENERAL Kit Number 34823 08 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Tools and Materials Required Separate purchases of a bearing sleeve 34822 08 a bearing assembly 9028 and a model specific sprocket spacer per P amp A Retail Catalog are required to complete installation See the P amp A Retail Catalog or the parts and Accessories section of www harley davidson com English only for any additional parts or accessories required for your model 2 ton press must be square to within 010 ram to table Inch lb torque wrench Foot lb torque wrench T15 TORX drive socket for inch Ib torque wrench 5 32 inch hex drive socket for inch lb torque wrench 5 16 inch hex drive socket for foot lb torque wrench 5 64 inch hex key wrench 1 16 inch hex key wrench 3 8 inch drive hand drill small tap handle suitable for 8 32 tap Tapping Fluid Press Fit Lube non drip Loctite 620 threadlocker and sealant AWARNING 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 installa
7. igure 19 To prevent rotation when dummy compensating sprocket shaft nut is tightened obtain locating screw from FLYWHEEL REBUILDING JIG and insert in deepest balancing hole at bottom of fly wheel assembly right side Turn flywheel slightly so that screw makes firm contact with flat on jig Tighten nut to 150 165 ft lbs 203 224 Nm d See Figure 15 Mount a dial indicator on the case half Set the indicator contact point on the end of the sprocket shaft e Standing on a stool for leverage if necessary firmly push down on the case as far as it will go while rotating it back and forth f Holding the case down zero the dial indicator gauge g Firmly pull up on the case as far as it will go while rotating it back and forth Stand on a stool for leverage if necessary h Holding the case up note the reading of the dial indicator Repeat the procedure to verify the reading i If the final or installed end play falls between 0 001 0 005 inch 0 025 0 127 mm proceed to the next step If end play is not within specification restart procedure with new Timken bearing set Remove dummy compensating sprocket shaft nut flat washer and spacer sleeve Lubricate bearing cones with clean H D 20W50 engine oil See Figure 20 Install new oil seal using pilot Nice bearing large flat washer and handle from SPROCKET SHAFT J04672 22 23 TIMKEN BEARING CONE INSTALLER part number HD 97225 55B a Verify that seal
8. inch out of the other side of the tap guide 19 Center the protruding tap over one of the 6 holes previ ously drilled 20 Apply 3 or 4 drops of tapping fluid in the hole you will be tapping Center the protruding tap over the hole with the tap guide across the centerline of the journal Apply pres sure to the tap guide at the centerline Center the tap in the hole and apply a constant light downward pressure to the tap handle as you turn the tap in a clockwise direction for 3 3 turns Downward pressure is required to start the formed tap Continue to turn the tap clockwise while relaxing the downward pressure Turn for a total of 12 revolutions turn the tap handle counterclockwise to fully retract the tap Do not pull on the tap handle This could result in damaged threads 21 Blow out the tapped hole and test the fitment of screw Repeat for the remaining 5 holes NOTES Taps will break if over stressed Do not pull or push sideways Do not rotate the tap into the case more than the 12 revolutions Do not tap without tap fluid If the tap starts to get hard to turn 4 of 10 before you have made 12 revolutions then retract the tap a couple of turns and add more tap fluid Slowly start tapping as above 22 Apply Loctite 620 to the threads and the under side of the screw head on all 6 screws Also apply about one drop to all 6 tap holes 23 See Figure 11 Using a torque wrench and a TORX T 15 driver torque each screw in a cr
9. isscross pattern to 25 30 in lbs 2 8 3 4 Nm 24 Remove the bottom plate and clean off all pieces of the tool and store it in the original container Do a visual check of the oil feed and drain holes These must be open and clean from any chips or Loctite isO5660 Left crankcase half Sprocket shaft Timklen bearing cone Sprocket Shaft Timken bearing cup Lock ring Spacer ring Oil seal Sprocket shaft spacer ove DEE Figure 11 Screw Torque Sequence ASSEMBLY Table 1 Tools PART NO SPECIALTY TOOL HD44358 Flywheel rebuilding jig HD 39361A Sprocket shaft oil seal installer HD 97225 55B Sprocket shaft Timken bearing cone installer 2246 4 Press installer plug 3 from kit 2246 1 Tool base 14 from kit J04672 Figure 12 Left Side Crankcase Assembly 1 See Figure 12 Obtain new Timken bearing set 2 3 and discard lock ring 4 NOTE Smaller OD of support tube is intended for Sportster models Verify that the Sportster pilot driver is not installed in opposite end of support tube or procedure will be interrupted as the two pilot drivers make contact 2 See Figure 21 Obtain the tool base 13 and press installer plug 3 and proceed as follows a SeeFigure 13 Set tool base 2 on table of hydraulic press with the larger OD topside b Center bearing cup on top of tool base with the let tered side up c With the inboard side up position cran
10. ite lubricant to threads of pilot shaft to prolong service life and verify smooth opera tion c Slide sleeve 5 over pilot until it contacts bearing cone 6 d Slide Nice bearing 4 and large flat washer 3 over pilot until contact is made with sleeve e Thread handle 2 onto pilot shaft 7 of 10 Table 2 Spacer Sizes isO5667 Inch Millimeter Part Number 0 0905 0 0895 2 299 2 273 9110 0 0925 0 0915 2 350 2 324 9120 0 0945 0 0935 2 400 2 375 9121 0 0965 0 0955 2 451 2 426 9122 0 0985 0 0975 2 502 2 476 9123 0 1005 0 0995 2 553 2 527 9124 0 1025 0 1015 2 604 2 578 9125 0 1045 0 1035 2 654 2 629 9126 0 1065 0 1055 2 705 2 680 9127 0 1085 0 1075 2 756 2 731 9128 0 1105 0 1095 2 807 2 781 9129 0 1125 0 1115 2 858 2 832 9130 0 1145 0 1135 2 908 2 883 9131 0 1165 0 1155 2 959 2 934 9132 0 1185 0 1175 3 010 2 985 9133 0 1205 0 1195 3 061 3 035 9134 is05672a Figure 18 Press Outer Bearing Cone to Sprocket Shaft NOTE While installing outer bearing cone carefully observe position of connecting rods If necessary stop frequently to verify that rods are still free If rods happen to move out of cylinder bore area they will be bent by the crankcase during the press pro cedure Bent connecting rods require replacement of the fly wheel assembly 16 See Figure 18 Rotate handle of tool in a clockwise direc tion until beari
11. kcase half over tool so that it rests flat on bearing cup d Start second bearing cup into bearing bore with the lettered side down e Slide press installer plug 1 through bore and both bearing cups into support tube f Center press installer plug under ram of hydraulic press Apply pressure until both bearing cups make firm contact with installed lock ring 5 of 10 isO5662 1 Press installer plug 2 Tool base 3 Press ram Figure 13 Sprocket Shaft Timken Bearing Cup Installer is05663 T ya Ss Dummy compensating sprocket shaft nut Sprocket shaft 3 Sprocket shaft nut N Figure 14 Dummy Sprocket Shaft and Nut NOTE Dummy sprocket shaft should be sufficiently polished so that it only requires the thumbs of both hands to lightly press on bearing cone J04672 Perform first end play check by simulating assembly a Fashion dummy sprocket shaft using parts used on Evolution models prior to introduction of one piece flywheel assembly Weld sprocket shaft nut part number HD 24017 80 to threads on inboard side of sprocket shaft part number HD 23909 80 See Figure 14 Obtain a dummy compensating sprocket shaft nut part number HD 40392 91 or 7 8 inch 14 nut from hardware store spacer sleeve and flat washer To verify complete thread engagement when nut is installed spacer sleeve must be about 2 1 4 inch long with a 1 3 4 inch OD and a 1 1 4 in ID Flat washer
12. lip garter spring is in place on both sides of seal b Thread pilot onto sprocket shaft until contact is made with shoulder c With the lettering facing outside slide oil seal over pilot until it contacts bearing bore d Set SPROCKET SHAFT OIL SEAL INSTALLER 1 part number HD 39361A over pilot until it contacts oil seal e Slide Nice bearing and large flat washer over pilot until contact is made with seal installer f Thread handle onto pilot shaft g Rotate handle in a clockwise direction until oil seal installer makes firm contact with crankcase stator mount h Remove handle flat washer Nice bearing seal installer and pilot from sprocket shaft Obtain model specific replacement sprocket shaft spacer See P amp A retail catalog Slide sprocket shaft spacer over end of sprocket shaft Push spacer into oil seal until seated against outer bearing cone Refer to the appropriate service manual to finish the engine assembly and installation is05670 1 Oil seal installer Figure 20 Sprocket Shaft Oil Seal Installer 9 of 10 SERVICE PARTS isO5600 Figure 21 Service Parts Timken Bearing Conversion Tool Table 3 Service Parts Table Item Description Quantity JIMS Part No 1 Press plate 959 2 2 Bottom locator plate 959 3 3 Press installer plug 2246 4 4 Drill bit 1 8 inch 2 1721 5 Drill stop
13. move the sleeve because it is not installing straight you will need to support the case around the sleeve on the inside of the left case It needs to be deep enough to receive the length of the sleeve and the tool press plug 4 The sleeve is 1 50 inches long You also need the press plug supplied in this kit to press the sleeve out Heat the case and sleeve to 200 degrees Then press the sleeve out of the case This would be the only time this sleeve is to be removed Ser j Figure 4 Insert Press Assembly 2 of 10 a Zi a v Ea p s 1 Screw 3 8 16 x 2 1 2 inch Figure 5 Install Press Plate Screw 11 Verify the bearing sleeve is square to the case bore Press from the top of the press plug until it has reached 2000 to 4000 psi and the sleeve s flange has stopped on the case 12 Remove the press plug from the press plate 13 See Figure 5 Apply lube to screw 1 and install screw through the press plate and thread it into the bottom locater plate Verify the dowel pin in the press plate is still located in the 1 8 inch hole in the sleeve Tighten screw to 25 ft lbs 33 9 Nm is05594 Figure 7 Drilling Oil Feed Hole J04672 14 See Figure 21 Table 3 and Figure 6 In this step the lock collars with be installed on the drill bits using the gauges milled into the press plate e Place stop collar 7 over drill bit 8 Place this assembly i
14. ng cone makes firm contact with spacer ring Inner and outer bearing cones must be tight against spacer ring for correct bearing clearance Remove handle flat washer Nice bearing sleeve and pilot from sprocket shaft Figure 17 Press Inner Bearing Cone to sprocket Shaft 10 See Figure 17 Rotate handle of tool in a clockwise direc tion until bearing cone bottoms on shoulder of sprocket shaft Remove handle flat washer Nice bearing sleeve and pilot from sprocket shaft Carefully place crankcase half over sprocket shaft so that it rests flat on installed bearing cone Slide spacer ring previously selected over sprocket shaft until it contacts bearing cone Place second bearing cone over sprocket shaft with the tapered side down Assemble SPROCKET SHAFT TIMKEN BEARING CONE INSTALLER part number HD 97225 55B onto sprocket shaft following procedure outlined under step 8 J04672 isO5669 1 Locating screw 2 Flywheel rebuilding jig Figure 19 Place Locating Screw in Balancing Hole to Prevent Rotation 8 of 10 18 19 20 21 Perform second end play check as follows a Gently tap case half to verify that it moves freely under its own weight Pull up and push down on case to verify that there is no noticeable up and down move ment b Install spacer sleeve flat washer and dummy compen sating sprocket shaft nut first used under step 3h c See F
15. nto the milled groove labeled OIL FEED on the face of the press plate Hold the drill bit firmly in the groove and slide the collar to the press plate Torque the stop collar set screw to 10 in Ibs 1 1 Nm e Use the same procedure as above and attach stop collar 5 to drill bit 4 using the milled groove OIL DRAIN Torque the stop collar set screw to 10 in Ibs 1 1 Nm e Use the milled groove MOUNTING HOLES for stop collar 15 and drill bit 11 Torque the stop collar set screw to 10 in Ibs 1 1 Nm NOTES Insert a drill bit into a clean drill chuck and tighten Spin the drill in the chuck and check for runout It is strongly suggested that runout should not exceed 0 005 inch The drill bit should be properly aligned bushing and lubricated Spin the drill into the bushing and maintain the angle while drilling the case While drilling it is necessary to clear the drilling chips To clear the chips retract the spinning drill bit but not out of the bushing If the chips are dry lubricate the bit As you drill deeper you will need to clear the chips more frequently Do not allow the stop collar to move up the drill bit by pushing too hard when drilling If you break a drill bit while drilling the feed or drain holes you must remove the bolt and press plate Carefully work the press plate off following the drill angle Remove any pieces of drill bit 15 See Figure 21 Table 3 and Figure 7 Use drill bit 8 assembly
16. tion of this kit could result in death or serious 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 Kit Contents See Figure 21 and Table 3 J04672 If replacement parts are needed contact JIMS at 805 482 6913 or www jimsusa com INSTALLATION 1 Remove and disassemble the engine as necessary to remove the left side engine case Bearings and seals must be removed from the left case Refer to the service manual for the disassembly procedures 2 Use an appropriate solvent to clean the left engine case Also clean the bearing sleeve 1 supplied in the kit 3 Apply Loctite 620 to the smaller inside diameter portion of the left case bearing bore 4 See Figure 1 Apply Loctite 620 using a cotton swab to the smaller portion of the outside diameter 2 surface of the bearing sleeve 1 5 Apply a spare amount of non drip press fit lube 3 to the larger outside diameter of the bearing sleeve 6 See Figure 2 Fit the bottom locater plate 1 to the to the outside of the case over the bearing bore The word BOTTOM will be at the bottom of the case when installed at the 6 o clock position 2 Apply Loctite to small outer diameter 3 Apply lubricant to large outer diameter Figure 1 Bearing Insert Preparation 1 of 10 is05589 O al
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