HOME Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement. Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use buffing crocus cloth on highly polished parts that are rusted. Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings. Bearings Always discard seals after removal. Do not use the same seal twice. Remove shields and seals from bearings before cleaning. Clean bearings with permanent shields and seals in solution.
O-Rings (Preformed Packings) Always discard O-rings after removal. Replace with new O- ring.To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation. Using compressed air to "spin dry" bearings can cause bearing to fly apart, which could result in death or serious injury. (00505b) Gears Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine. Always check gears for damaged or worn teeth. Let bearings stand and dry. Do not dry with compressed air.
Do not spin bearings while they are drying. Remove burrs and rough spots with a honing stone or crocus cloth before installation. Lubricate mating surfaces before pressing gears on shafts. TOOL SAFETY Shafts Air Tools If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force. • Always use approved eye protection equipment when performing any task using air-operated tools. • On all power tools, use only recommended accessories with proper capacity ratings. Shafts fitted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines.
Discard together tightly. Do not exceed air pressure ratings of any power tools. Part Replacement Always replace worn or damaged parts with new parts. • Never point an air tool at yourself or another person. Exhaust System Leakage • Protect bystanders with approved eye protection. In the event of an exhaust system leak at a muffler or header pipe connection location, disassemble and clean all mating surfaces. Replace any damaged components. If leak still exists, disassemble and repair the leak by applying a bead of Harley- Davidson High-Performance Sealant (Part No. 99650-02) (or an equivalent 02 Sensor/Catalyst-safe alternative).
Reassemble components, wipe off any excess sealant and allow adequate curing time following sealant product instructions before oper- ating vehicle. Wrenches • Never use an extension on a wrench handle. • If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go. • Never cock a wrench. • Never use a hammer on any wrench other than a STRIKING FACE wrench. CLEANING • Discard any wrench with broken or battered points. Part Protection • Never use a pipe wrench to bend, raise or lift a pipe. Pliers/Cutters/Pry bars Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions.
Use a grease- proof barrier material. Remove the rubber part if it cannot be properly protected. • Plastic- or vinyl-covered pliers handles are not intended to act as insulation. Do not use on live electrical circuits. • Do not use pliers or cutters for cutting hardened wire unless they were designed for that purpose. Cleaning Process • Always cut at right angles. Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before priming and repainting. • Do not use any pry bar as a chisel, punch or hammer. 2009 VRSC Service: Maintenance 1-3 tapered splines.
plines are clean, d lace. Press matin aces of new parts Discard • Do not exceed air p ry and • Bits should be plac g parts hammers are opera • Disconnect the air . attaching a bit.