Harley Davidson Sportster (1959 to 1969). Service manual - page 6
Before pressing in new bushings, note location of
original dowel pin holes for reference when drilling new holes. When
drilling new holes, be sure to locate holes 1/8 in. or more from
original dowel pin holes.
Use a smooth surfaced disc or plate slightly larger than flange when
pressing bushing into position. Be sure bushing flanges are seated tight
against gear-case cover and/or crankcase idler gear bushing.
After new bushings have been pressed in, they must be dowel pinned with
cover bushing pins to prevent them from turning. Drill a hole with a
number 31 drill, 9/32 in. deep, through bushing flange and into aluminum
so when dowel pin (28, Fig. 3D-11) is driven in and bottomed, its end
will be slightly below face of bushing flange. Peen bushing around dowel
pin hole to prevent pin from coming out.
After all bronze bushings have been pressed in and dowel pinned, all but
the idler gear bushings must be line-reamed.
