JIMS 911 - User Manual

IInnssttrruuccttiioonn SShheeeett FFoorr TTooooll ##991111
Rev N/C
3/09
No.911-IS
11
555 Dawson Drive, Camarillo, CA 93012 Phone 805-482-6913 • Fax 805-482-7422
A Division of Thiessen Products, Inc.
H-D CRUISE DRIVE 6-SPEED TRAP DOOR BEARING REMOVER / INSTALLER TOOL
Use on any H-D 6-speed Cruise Drive transmission 2006 to present
This tool is designed to function on a work bench tool and removes or installs Cruise Drive trap door bearings without
using an arbor press.
Other recommended JIMS tools for H-D Cruise Drive 6-speed:
No. 989 Mainshaft pulley locknut socket tool No. 984 Trap door remover tool
No. 900 Main drive gear and bearing remover / installer tool No. 985 Shift fork shaft remover tool
No. 972 Main drive gear seal installer tool
No. 992 Modular transmission stand, all Twin Cams
No. 349920-84 Mainshaft race remover
Read complete instructions thoroughly before disassembling or
assembling. Refer to figure No.'s, parts lists and reference drawings.
NOTE: IF YOU DO NOT KNOW WHAT YOU’RE DOING , DO NOT
DO IT! ALWAYS WEAR SAFETY GLASSES OR OTHER FACE
AND EYE PROTECTION SUCH AS A FULL FACE WITH EYE
PROTECTION. JIMS IS NOT RESPONSIBLE FOR DAMAGE,
INJURY, YOUR WORK, OR THE QUALITY AND SAFETY OF
YOUR WORK.
OTHER TOOLS RECOMMENDED FOR USE WITH THIS TOOL
2 - 3/4'' Socket or box end wrench 1 - 3/8" Ratchet wrench
1 - 3/16" Allen wrench or Allen socket 1- Quality retaining ring pliers
1- Safety glasses 1 - H-D Service Manual
Removing The Old Trap Door Bearing
1. Refer to H-D Service Manual for tear down of the transmission assembly
to the point of removing the trap door from the case using JIMS
®
tool No 984. Also you will need to remove mainshaft
and countershaft gear assemblies from door bearings per service manual.
2. Remove retaining rings that sit against the two door bearings on trap door.
Always wear safety glasses while performing this service.
3. We will instruct you on removing the front door bearing. Notice the two
dowel pins on the outer side of trap door.
See Fig 2. Set tool lower plate
No.
911-1 on trap door and locate on dowel pin. You should have the
plate lasered letter "B" facing upward toward you.
See Fig 2.
4. Next place the upper tool plate No. 911-2 on top of lower plate No. 911-
1. The upper plate should have laser marked side with the letter "B" facing
you. Now install lightly lubed three 1/4" Allen screws No.
1203. into the
three 1/4" holes on top of the upper plate thus attaching tool to trap door.
Torque 3 allen screws to
100 inch pounds. See Fig 3.
5. Next lube threads on tool screw No.1024. and install into No. 911-2 upper
plate. Thread screw into bearing I.D. until screw is about a 1/2" past bear-
PARTS AVAILABLE SEPARATELY
No. Qty. Description Part No.
11 Lower plate 911-1
21 Upper plate 911-2
31 Installer pilot 1077-2
41 Screw 1024
53 Allen screw 1/4-20 x 2" 1203
61 Nut 5/8-18 1065
71 Washer 5/8 SAE 1064
2
FIG 1
5 4 7 6
3
1
FIG 2
Dowel
Pin
Dowel
Pin

Summary

Remove Trap Door Bearing

Remove Retaining Rings

Remove retaining rings that sit against the two door bearings on trap door.

Position Lower Tool Plate

Place lower plate on trap door, aligning on dowel pins with letter 'B' facing upward.

Attach Upper Tool Plate

Secure upper plate to lower plate with three 1/4" Allen screws.

Install Removal Screw

Lube and install the main tool screw into the upper plate for bearing removal.

Install Trap Door Bearing

Prepare Bearing Surfaces

Clean trap door bearing surface and retaining ring groove as needed.

Install Front Door Bearing

Lube bearing O.D., position over bore, and insert installer pilot into bearing I.D.

Position Tool for Installation

Place lower and upper plates on trap door, aligning with dowel pins.

Secure Tool Plates

Attach upper plate to lower plate with Allen screws, torquing to 100 inch pounds.

Install Installer Screw

Lube and install the main tool screw clockwise to seat the bearing.

Install Retainer Ring

Install the new trap door bearing retainer ring into the trap door.

Install Rear Bearings

Use plates with letter "A" facing you for rear bearing installation.

Overview

1. Function Description
2. Important Technical Specifications and Components
3. Usage Features
4. Removing the Old Trap Door Bearing
5. Installing New Trap Door Bearing
6. Maintenance Features
7. Other Recommended JIMS Tools
8. General Safety and Usage Advice

The JIMS 911-IS is an instruction sheet for the Tool #911, a specialized device designed for the removal and installation of H-D Cruise Drive 6-Speed trap door bearings. This tool is specifically engineered for use with any H-D 6-Speed Cruise Drive Transmission manufactured from 2006 to the present. Its primary function is to facilitate the servicing of these bearings without the need for an arbor press, making it suitable for use on a workbench.

Function Description:

The JIMS Tool #911 serves a dual purpose: removing old trap door bearings and installing new ones. It operates by attaching directly to the trap door assembly, allowing for controlled extraction and insertion of the bearings. The tool utilizes a screw mechanism to apply force, either pulling out an old bearing or pressing in a new one, ensuring precise and damage-free operation. This eliminates the need for heavy-duty shop presses, making the process more accessible for mechanics and technicians working on Harley-Davidson motorcycles.

Important Technical Specifications and Components:

The JIMS Tool #911 consists of several key components, each with a specific role in the bearing service process. These parts are also available separately for replacement:

• Lower plate (Part No. 911-1): This plate serves as the base that attaches to the trap door. It features a laser-etched "B" side for proper orientation during the front bearing service and an "A" side for the rear bearing service.
• Upper plate (Part No. 911-2): This plate sits on top of the lower plate and also has laser-etched "B" and "A" sides for orientation. It houses the main screw mechanism.
• Installer pilot (Part No. 1077-2): This component is crucial for installing new bearings. It guides the new bearing into the bore, ensuring proper alignment and preventing damage during the pressing process.
• Screw (Part No. 1024): This is the primary threaded rod that applies the necessary force for both removal and installation. Its threads must be lubricated for smooth operation.
• Allen screws (Part No. 1203, 3 pieces): These 1/4-20 x 2" Allen screws are used to secure the upper plate to the lower plate and the trap door, ensuring a rigid assembly. They require a specific torque of 100 inch-pounds.
• Nut (Part No. 1065, 5/8-18): This nut works in conjunction with the main screw (Part No. 1024) and washer to apply force during bearing removal.
• Washer (Part No. 1064, 5/8 SAE): Placed between the nut and the upper plate, this washer helps distribute the load evenly.

Usage Features:

Removing the Old Trap Door Bearing:

1. Preparation: Before using the Tool #911, users must refer to the H-D Service Manual for the complete transmission assembly tear-down, including removing the trap door using JIMS tool No. 984, and disassembling the mainshaft and countershaft gear assemblies from the door bearings.
2. Retaining Ring Removal: The retaining rings against the two door bearings on the trap door must be removed. Safety glasses are mandatory during this step.
3. Tool Setup (Front Bearing): For the front door bearing, the lower plate (911-1) is placed on the trap door, aligning with a dowel pin. The "B" side of the plate should face upward.
4. Upper Plate Attachment: The upper plate (911-2), with its "B" side facing upward, is then placed on top of the lower plate. Three 1/4" Allen screws (1203) are lightly lubed and installed into the upper plate, securing the tool to the trap door. These screws are torqued to 100 inch-pounds.
5. Bearing Extraction: The threads of the main screw (1024) are lubricated and installed into the upper plate, threading into the bearing's inner diameter until about 1/2" past the bearing. A washer (1064) and nut (1065) are then installed onto the screw, ensuring full thread engagement.
6. Removal Operation: The trap door is secured in a bench or soft-jaw vice. The main screw (1024) is turned counter-clockwise using a 3/4" box end wrench, socket, or ratchet until the bearing comes free from the door.

Installing New Trap Door Bearing:

1. Cleaning and Preparation: The trap door bearing surface and retaining ring groove must be inspected and cleaned. The trap door is secured on a bench or vice with soft jaws.
2. Bearing Lubrication and Positioning: The outer diameter of the new door bearing is lubricated. The bearing is then positioned squarely over its bore.
3. Installer Pilot Insertion: The installer pilot (1077-2) is inserted into the inner diameter of the new bearing.
4. Tool Setup (Front Bearing): Similar to removal, the lower plate (911-1) is placed on the trap door, aligning with a dowel pin, with the "B" side facing upward.
5. Upper Plate Attachment: The upper plate (911-2), with its "B" side facing upward, is placed on the lower plate. Three lightly lubed 1/4" Allen screws (1203) are installed and torqued to 100 inch-pounds, attaching the tool to the trap door.
6. Bearing Installation: The threads of the main screw (1024) are lubricated and installed into the upper plate. The screw is turned clockwise using a 3/4" box end wrench, socket, or ratchet until the bearing seats firmly in the bearing bore.
7. Retainer Ring Installation: A new door bearing retainer ring is installed into the trap door.
8. Rear Bearing Installation: For the rear trap door bearings, the upper and lower plates are attached to the door with the engraved letter "A" facing the user, following the same instructions as for the front bearing.

Maintenance Features:

• Lubrication: Regular lubrication of the main screw (Part No. 1024) threads is essential for smooth operation and to prevent wear.
• Cleaning: Keeping the tool components clean, especially the bearing surfaces and retaining ring grooves, ensures proper function and longevity.
• Component Replacement: All individual parts of the tool are available separately, allowing for easy replacement of worn or damaged components rather than requiring the purchase of an entirely new tool. This contributes to the tool's long-term usability and cost-effectiveness.
• Safety: The instructions emphasize the importance of wearing safety glasses or other face and eye protection during all operations, highlighting a key maintenance aspect related to user safety.
• Torque Specifications: Adhering to the specified torque of 100 inch-pounds for the Allen screws ensures the tool is securely attached and prevents damage to the trap door or the tool itself.

Other Recommended JIMS Tools:

For comprehensive transmission service, JIMS recommends several other tools:

• No. 989 Mainshaft pulley locknut socket tool
• No. 900 Main drive gear and bearing remover / installer tool
• No. 972 Main drive gear seal installer tool
• No. 992 Modular transmission stand, all Twin Cams
• No. 349920-84 Mainshaft race remover
• No. 984 Trap door remover tool
• No. 985 Shift fork shaft remover tool

General Safety and Usage Advice:

The instruction sheet strongly advises users to read all instructions thoroughly before beginning any disassembly or assembly. It also includes a critical safety note: "IF YOU DO NOT KNOW WHAT YOU'RE DOING, DO NOT DO IT! ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS A FULL FACE WITH EYE PROTECTION. JIMS IS NOT RESPONSIBLE FOR DAMAGE, INJURY, YOUR WORK, OR THE QUALITY AND SAFETY OF YOUR WORK." This underscores the importance of user competence and safety precautions. The tool is designed for use by individuals familiar with motorcycle mechanics and the specific procedures outlined in the H-D Service Manual.

JIMS 911 Specifications

General

Brand	JIMS
Model	911
Category	Tools
Language	English