Harley-Davidson Dyna 2008 - TRANSMISSION ASSEMBLY 7.5; REMOVAL

7.5TRANSMISSION ASSEMBLY
REMOVAL
NOTE
Leave the transmission case in the frame unless the case itself
requires replacement. For illustration purposes, some photo-
graphs may show the case removed. For information on case
removal see 7.7 TRANSMISSION CASE.
1. Remove exhaust system. See 4.16 EXHAUST SYSTEM.
2. Remove primary chaincase cover, clutch assembly,
primary chain, compensating sprocket assembly and
primary chaincase. See 6.4 PRIMARY CHAINCASE
HOUSING, Removal.
3. Remove the bearing inner race from the transmission
mainshaft. See 6.4 PRIMARY CHAINCASE HOUSING,
Mainshaft Bearing Inner Race.
4. Remove the clutch release cover from the transmission
side door. See 7.4 CLUTCH RELEASE COVER, Removal
and Disassembly.
5. See Figure 7-7. Remove oil slinger assembly from main-
shaft. Remove push rod.
6. Remove transmission top cover, leaving the cover gasket
in place.
7. See Figure 7-8. Place shifter cam pawl on top cover
gasket.
4
1
3
5
6
2
sm03013
1. Retaining ring
2. Thrust washer (2)
3. Throw out bearing
4. Oil slinger
5. Push rod
6. Push rod end, left side
Figure 7-7. Push Rod Assembly
2
1
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1. Shifter pawl
2. Top cover gasket surface
Figure 7-8. Set Shifter Pawl on Gasket
NOTE
Only remove and install sprocket nut while transmission is in
vehicle frame. Trying to remove and install sprocket nut with
transmission in transmission stand may cause damage to
transmission or stand.
8. If main drive gear is to be removed, see 7.6 MAIN DRIVE
GEAR AND BEARING, Removal.
9. See Figure 7-9. Remove oil spout fastener (8), oil spout
(6) and o-ring (7). Discard o-ring.
NOTES
• The main drive gear bearing and retainer must be replaced
if the main drive gear is removed. The bearing will be
damaged during the removal procedure.
• See Figure 7-10. Do not attempt to remove shafts by tap-
ping them out from opposite side. If you try to remove the
shafts by tapping them with a hammer, you will damage
the side door bearings. If the side door sticks or binds on
the ring dowels, pry open using indents at each side of
side door.
10. Cover mainshaft clutch hub splines with tape to prevent
the splines damaging the main drive gear bearings.
11. See Figure 7-11. Remove the transmission side door
mounting hardware. Remove exhaust bracket, if equipped.
Pry the side door loose and remove side door, mainshaft,
countershaft and shifter cam from transmission case as
an assembly. Discard gasket.
2008 Dyna Service: Transmission 7-7