Harley Davidson DUO-GLIDE 74 OHV. Service manual (1959) - page 5
To ream pinion shaft bushing, insert reamer pilot in right crankcase
roller race. Insert 9/16 in. Pinion Shaft Cover Bushing Reamer, Part No.
94805-57, through pilot and push into cover bushing until it bottoms
(see Fig. 3D-7), then give reamer one complete turn to size bushing.
Rotate reamer the same direction (clockwise) during extraction.
To ream cam gear cover bushing, insert Cam Gear Shaft Bushing Reamer,
Part No. 94802-36, through needle bearing in crankcase, into cover
bushing. Turn reamer until it bottoms in gearcase cover.
Bushings in intermediate and idler gears may be pressed out on an arbor
press using a suitable drift pin, and new bushings pressed in.
ASSEMBLY
Before assembling gear train, determine amount of end play in breather
gear as follows: Assemble breather gear and dry cover gasket to gearcase.
Select spacer washer (use washer disassembled unless it is known to give
incorrect spacing) and position on
end of breather gear. Place a steel straightedge
across gearcase at spacer. With thickness gauge, measure distance
between straightedge and spacer. Subtract .014 in. (thickness of
compressed gasket) from this figure to determine gear end play. An end
play tolerance of .005 to .008 in. is correct. If end play exceeds
maximum, insert thicker spacer. Breather valve and gear spacer washers
are available .115, .120 and .125 in. thick.
Establish proper cam gear end play as follows: Install thrust washer,
spacing washer and cam gear. Position cover gasket and secure cover with
at least four screws. Measure cam shaft end play between cam gear and
cover bushing with thickness gauge through tappet guide hole in gearcase.
End play should be from .001 to .005 in. If measurement is under or over
tolerance, remove cover and replace spacing washer with one to give
suitable clearance. Cam gear spacing washers are available .050, .055,
.060, .065 and .070 in. thick.
Make final gearcase assembly including all parts in approximate reverse
of disassembly order. Fig. 3D-9 shows use of Tool Part No. 96830-51 to
install pinion gear. Breather, cam, pinion and intermediate gears
contain timing marks which must be aligned or matched as shown in Fig.
3D-8. Rotate gear train and note if it revolves freely. A bind indicates
gears are meshed too tightly. Make sure intermediate and idler gear
spacers are assembled to their respective shafts.
Position new cover gasket and cover and secure with all cover screws.
Pour about 1/4 pint of engine oil over gears to provide initial
lubrication before securing cover.
Assemble remainder of gearcase, generator and circuit breaker in reverse
of order removed.
