NO.

295 NOVEMBER 1, 1949

MODEL 125 FLYWHEEL and CONNECTING ROD ASSEMBLY TOOL SET

.
'.
. ASSEMBLY PART NO. 96125-49 . .

P a r t No. Description Part No. Description

A. 96138-49 Flywheel T a p e r e d S p a c e r . G. 96134-49 C r a n k P i n P i l o t Aligning

".
- C.
A r m a t u r e Shaft Installing
Plate.
Sprocket Shaft Installing I.
Sleeve.
H. 96136-49 C r a n k P i n Aligning Pilot.
96132-49 Shaft Locating P r e s s Block.
Plate. J. 96130-49 D r i f t and P i l o t Pin.
D. 96202-49 R e c e s s Clean-up Tool. K. 96135-49 C f a n k P i n Press Cap.
E. 96207-49 Staking Punch. L. 96137-49 Flywheel Support Plate.
F. 96133-49 P r e s s Block.
Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.
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No. 295 Page 2.
Because shafts i n Model 125 flywheel assembly a r e a straight p r e s s fit in the *

flywheels, and main shafts m u s t be p r e s s e d into wheels to a specified depth to c o r -

reetly position generator a r m a t u r e and engine sprocket, jig and fittings described
a r e n e c e s s a r y for accurate assembly. With this jig shafts c a n be s t a r t e d a n d p r e s s -
4
e d in, in perfect alignment with flywheel holes.

If directions a r e followed closely, completed a s s e m b l y will r e q u i r e little, if

any, further truing between c e n t e r s a s shown in Illus. 12.

These a r e precision tools; they can be easily damaged through rough usage;
handle with c a r e .

Note: When r e m o v i n g a r m a t u r e shaft

bearing, i n s e r t a nut about 1/2" hex be-
tween end of shaft a n d puller s c r e w , to
prevent puller s c r e w f r o m damaging end
of shaft.

.. ~
..
ake a p u l l i r b a r attachment f o r
-Davidson wed*e puller, Part No.
48 a s shownin-Iklus. 1. ~ u l l e ; b a r
c& be made out oi a pi,ece of f l a t stock
ahout. l f 2 " thick. 1-1/2" wide, and 4" long.
,Fuller s c r e w ff om one of s e v e r a l i l a r l e y -
i avid son pullers c a n b e u ~ e ds, i z e & t h r e a d
1/2*- 18. Two cap.. s c r e w s , 3/8" - 16
thread, about 3-1/2" long a r e required to
;' attach b a r t o wedge: Ends, of puller b a r
musk be slotted;,7/16"'wide and about 1"
deep t o allow f o r variable,. wedge width.
With described p a e r a v ~ i l a b l e ,s e c u r e
flywheel shaft i n a vise fitted with copper
jaw caps and pull bearing; turn assembly
over and pull the other bearing.
REMOVING COMPRESSION PLATES
When wedge puller i s used to remove
sprocket and a r m a t u r e shaft bearings a s
shown i n Illus. 1, compression plates m a y
come out of t h e i r r e c e s s e s a s b e a r i n g s
a r e removed. Hawever, if they do not,
remove the plates in following m a n n e r .
Drill a s m a l l hole a t edge of com-
p r e s s i o n plate just d e e p enough to p e r -
m i t using a s h a r p pointed p r y below edge
of plate a s shown i n Illus. 2. The plate
will readily b r e a k through t h e staking
which o v e r 1a p s edge of plate at eight
_
equally spaced locations. Flywheels a r e
now r e a d y f o r disassembly a s in Illus. 4.

Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.

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No. 295 Page 3

DISASSEMBLING F L Y WHEELS

Slide "Flywheel Support Plate" ( L ) ,

between flywheels andplace on two blocks
a s shown in Illus. 4.

Blocks m u s t be over 5" high s o end

of main shaft will not c o m e in contact with
bench before flywheels a r e fully s e p a r a t -
ed. Then, using 'Drift and Pilot Pin" (J),
tapered end against c r a n k pin, p r e s s out
c r a n k pin with connecting r o d and lower
flywheel attached.

Follow s a m e procedure to remove

c r a n k pin f r o m other flywheel.

COMPRESSION PLATE RECESS

CLEAN-UP TOOL

After compression plates have been

removed a s shown in Illus. 2, c l e a n up
compression plate r e c e s s in eachflywheel,
using "Recess Clean-up Tool." (D).

~ i r s put
t a thin f i l m of oil on shaft
and slide tool onto it. H o 1d tool down
f i r m l y with one hand, and with other hand
turn clockwise a s shown in Illus. 3. T h e
cutter will remove old staking f r o m r e -
c e s s . Caution: Do not pull tool counter-
clockwise, or a broken cutting edge will
result.

Cutter i s adjustable to compensate

for wear and sharpening. Adjust cutter
so i t completely cleans up staking arourd
recess.

Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.

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No. 295
PRESSING . OUT M A W SHAFTS
.
, . ..
{Note: ' In m
wheel assembly r e q u i r e s r e p a i r , only
crank pin, connecting rod and rod b e a r -
i n g s heed be removed. . .. . , shafts a r e a r e a l tight p r e s s fit in wheels,
__Mainshafts ( a r m a t u r e a n d s p r o c k e t )
a r e seldomfound worn o r damaged to such
extent that replacement is required. How-
e v e r , in any instance when flywheel a s -
sembly is removed f r o m engine and taken
apart, if t h e r e is the slightest possibility
that main shafts have shifted f r o m origi-
nal specified depth, to which they w e r e
p r e s s e d i n t o flywheels, they shouldbe par-
tially p r e s s e d out of wheels, then p r e s s e d
back to specified depth, with jig fittings
provided f o r that operation.
T h e things m o s t likely to cause main
shafts to shift f r o m their locations a s o r i -
Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.
Page 4
ginally assembled, a r e hammering shafts
' when removing engine sprocket o r gen-
e r a t o r a r m a t u r e , o r hammering shafts o r
c r a n k c a s e s , w h e n disassembling wheels
f r o m o r into crankcases. E v e n though
the impact of a moderate h a m m e r blow i s
sufficient to move them.)
Withflywheels s e p a r a t e d a s de-
s c r i b e d u n d e r "Disassembling Flywheels"
and shown in Illus. 4, the sprocket shaft,
a r m a t u r e shaft, o r both, c a n be removed
for replacement, if n e c e s s a r y . See Illus. 5.
Placeflywheelwithshaft in it, on two
blocks, s h af t downward between blocks.
Bring the two blocks a s c l o s e to shaft a s
possible. Again u s e the Drift and Pilot
~ i n ( w i t htapered end against end of shaft).
and p r e s s out shaft.
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No. 295
ILLUS. 6
REASSEMBLY
After flywheels h a v e been d i s a s -
sembled, thoroughly cleaned, faulty p a r t s
discarded, and connecting rod serviced a s
necessary, oil shafts and h o l e s i n fly-
wheels andproceed to assemble flywheels
in following manner.
- -
INSTALLING MAIN SHAFTS
F i r s t install key in a r m a t u r e shaft.
P l a c e tapered end of shaft i n "Shaft Lo-
cating P r e s s Block" (I). I n s e r t straight
end of shaft through uShaftInstalling Plate"
(B) into flywheel. I n s e r t "Pilot Pin" (J)
through hole in P r e s s Block, hole in In-
- stalling P l a t e and crank pin hole in fly-
wheel. Support wheel with a block placed
directly underneath flywheel center hole
and p r e s s shaft into flywheel a s shown in
Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.
Page 5
Illus. 6. Be s u r e that P r e s s B l o c k i s
presseddown tight against Installing P l a t e
(B).This procedure p r e s s e s shaft the c o r -
r e c t depthinto flywheel and locates a r m a -
t u r e shaft keyway i n relation with crank-
pin h o l e s o that c o r r e c t ignition timing
can be attained, after a r m a t u r e and c i r -
cuit b r e a k e r c a m a r e installed.
Shafts m u s t be a v e r y tight p r e s s fit
in flywheels. When a shaft has only a very
light p r e s s f i t in flywheel it i s probably
because flywheel hole has become enlarg-
ed. Wheel i n this condition should be dis-
carded and new one used.
Follow this s a m e procedure when
installing sprocket shaft, using "Sprocket
Shaft Installing Plate" (C); however, key
way location i n relation to crank pin can
be disregarded.
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No. 295 Page 6

Illus. 7 shows the C r a n k P i n Pilot

being s e c u r e d while being held i n align- ,
ment with the C r a n k P i n Aligning Sleeve. ,
Illus. 8 s h o w s Aligning Sleeve removed
after Crank P i n Pilot has been secured.

ILLUS. 7

INSTALLING CRANK PIN PILOT

Attach "Crank P i n Aligning Pilot"

(H) t o c r a n k pin a s shown i n Illus. 7. Hold
s m a l l t a p e r e d end a g a i n s t one end of c r a n k
p i n , then p a s s s c r e w through c r a n k pin
f r o m opposite end. Do not tighten as yet.

Next s l i d e "Crank P i n P i l o t Aligning

Sleeve" (G) o v e r C r a n k P i n Aligning P i l o t
and c r a n k pin, (heavily c h a m f e r e d end to-
ward connecting r o d). Tighten aligning
pilot s c r e w s e c u r e l y and r e m o v e s l e e v e .

PRESSING CRANK PIN INTO

F L Y WHEEL
After end of c r a n k p i n h a s b e e n c o a t -
ed with a thin f i l m of engine oil, place f l y -
wheel i n which a r m a t u r e shaft i s installed
on two blocks and i n s e r t C r a n k P i n P i l o t
into c r a n k pin hole as shown in Illus. 9.
P l a c e " P r e s s Cap" (K) on end of pin and
p r e s s pin into flywheel until i t bottoms.

Remove P r e s s Block, a l s o C r a n k
P i n Pilot, and i n s t a l l P i l o t on opposite end
of c r a n k pin i n s a m e m a n n e r a"s shown i n
ILLUS. 8 Illus. 7 a n d explained u n d e r I n s t a l l i n g
C r a n k P i n Pilot."
CRANK PIN PILOT ALIGNING SLEEVE

Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.

 SHUJ? UUJ?L
No. 295 ' pi+!; 3
::I ,

flywheel. P u s h upper plate downward ''by

hand" until Opper flywheel contacts end of
c r a n k pin. Using " P r e s s Block" (F) over
protruding end of Crank Pin Aligning Pi-
lot, p r e s s down until upper flywheel bot-
toms against connecting r o d t h r u s t washer.

REINSTALLING COMPRESSION PLATES

Support flywheels a s shown in Illus.

11 a n d install compression plates, p r e -
ferably new plates if old plates a r e in the
least damaged or out of shape.

U s i n g Compression P l a t e R e c e s s
Clean-up Tool a s a guide, stake compres-
sion plates in place by upsetting edge of
flywheel r e c e s s with "Staking Punch" (E).
Note that end of this punch i s angled, and
i s to be used with longer tip outward.

Make s u r e compression plates a r e

well secured. P l a t e s have a tendency to
spring, and if not s e c u r e l y installed may
b r e a k away f r o m staking. A loose plate
i s not only noisy but a l s o lowers engine
performance due to below n o r m a l crank-
c a s e compression.

PRESSING FLY WHEELS TOGETHER

Flywheels can n o w be p r e s s e d to-

gether in the following manner. See Illus.
10.

P l a c e flywheel that h a s crank pin and

connecting r o d installed o n "Armature
Shaft Installing plate" (B). P l a c e flywheel
in which sprocket s h a f t i s installed on
Sprocket Shaft Installing Plate.

Note t h a t Sprocket Shaft Installing

Plate is ntarked on one side "This side
up.
" Flywheel must be held against op-
posite side.

Holding flywheel against plate, s t a r t

plate onto guide pins attached to A r m a t u r e
Shaft Installing Plate. At the s a m e time
- guide Crank P i n Pilot through flywheel,
then through hole i n upper installing plate
which corresponds with c r a n k pin hole in

Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.

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No. 295 Page 8

Note: Shaft bearings h a v e only a

light p r e s s f i t , therefore, t h e r e i s little
danger of moving shafts in flywheels when
pressing bearings on.

Caution: When installing bearings -

do not d r i v e on with a hammer.

TRUING FLY WHEELS

Using ' F l y w h e e l Truing Device"

P a r t No. 11962-X c h e c k a r m a t u r e a n d
sprocket shaft run-out a s shown in Illus.
12. Shafts must run t r u e within.001".
This is one half graduation on indicator
scale. I€ a r m a t u r e a n d s p r o c k e t shafts
run high near the c r a n k pin, install a "C"
clamp a b o v e c r a n k pin a n d apply light
p r e s s u r e . With clamp in place s t r i k e fly-
wheels very lightly above crank pin. Take
another reading, if shafts s t i l l do not run
t r u e repeat operation again. Shafts m u s t
be within specification, s o a r m a t u r e will
r u n t r u e , otherwise there will be exces-
sive "brush hop" and arcing.

INSTALLING ARMATURE SHAFT

BEARING
Again using two blocks and Flywheel
Support Plate a s shown i n Illus. 13, p r e s s
a r m a t u r e shaft bearing and sprocket shaft
inner bearing on t h e i r respective shafts.

Placebearing on shaft. Use a sleeve

or a piece of 3/4" pipe no l e s s than 3"
long, over shaft against ball bearing inner
race. P r e s s bearing on shaft'until i t bot-
toms.

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No. 295
ILLUS. 14
INSTALLING F L Y WHEEL ASSEMBLY
I N CRANKCASES
Prepare crankcases f o r assembly:
See that t r a n s m i s s i o n a n d shifter p a r t s
a r e correctly a s s e m b l e d in left c a s e .
Thoroughly c l e a n c r a n k c a s e joint f a c e s .
I n s e r t "Flywheel T a p e r e d S p a c e r "
(A) between the two flywneels o p p o s i t e
c r a n k pin, upper e n d of connecting r o d
between the two prongs of s p a c e r a s shown
in Illus. 14. The purpose of this s p a c e r
is to prevent closing up flywheels and thus
throwing w h e e 1 s h a f t s out of alignment
w h e n installing f 1y w h e e 1 a s s e m b l y in
c r a n k c a s e s . Do not f o r c e s p a c e r between
flywheels, j u s t snug is a l l that i s n e c e s s -
ary.
Using a t o r c h , h e a t left c r a n k c a s e
around bearing b o r e enough s o b e a r i n g
will s l i d e e a s i l y into c r a n k c a s e a s fly-
wheel a s s e m b l y is i n s t a l l e d i n left c a s e .
D o not apply f l a m e d i r e c t l y a g a i n s t o i l
s e a l . NOTE: At this p ~ i n t ,o b s e r v e that
o i l s e a l is snug agalnst i t s retalning rlng.
I n s e r t flywheel a s s e m b l y in left c a s e .
It 1s s e a t e d in left c a s e when s p r o c k e t
shaft bearing s e a t s against o i l s e a 1 r e -
taining rlng.
Harley Hummer Club, Inc. - Used by Permission of Harley-Davidson, Inc.
Page 9
Next heat r i g h t c r a n k c a s e around
b e a r i n g b o r e and apply heat around open
dowel pin holes. Apply s e a 1 e r to joint
f a c e s of both c a s e s .
Install right c r a n k c a s e . I n s e r t and
s e c u r e l y tighten a l l c r a n k c a s e c l a m p
screws.
T h e next a s s e m b l y operation i s in-
stalling s p r o c k e t shaft outer b e a r l n g .
However, b e f o r e this c a n b e done, i t m u s t
b e d e t e r m i n e d how many s h i m s a r e r e -
quired behind b e a r i n g t o obtaln c o r r e c t
c l e a r a n c e between b e a r i n g inner r a c e and
back f a c e of engine s p r o c k e t .
The d e s l r e d c l e a r a n c e i s ,003" to
.012". To attain this c l e a r a n c e , s h ~ m s
a r e provided ' .007" thick. T o d e t e r m i n e
how many s h i m s a r e needed, t e m p o r a r i l y
i n s e r t , Instead o f b e a r i n g , a 45" model
r e v e r s e g e a r s p a c i n g c o l l a r , p a r t No.
2296-33A. Spacing c o l l a r i s approximat-
ely the s a m e width as b e a r i n g No. 9008.
I n s e r t this c o l l a r with l a r g e d i a m e t e r in-
ward ag3inst oil s e a l .
Install s p r o c k e t and s e c u r e l y tighten
s p r o c k e t nut. U s e f e e l e r gauge to d e t e r -
mine t o t a l c l e a r a n c e between back f a c e of
s p r o c k e t and c o l l a r . It c a n now be c a l c u -
lated how m a n y .007" thick s h i m s a r e r e -
q u i r e d to r e d u c e t h e total c l e a r a n c e t o
approximately .010". S p r o c k e t and gaug-
ing c o l l a r c a n now be r e m o v e d and c o r -
r e c t number of s h ~ m si n s e r t e d . Heat c a s e
around b e a r i n g hole a n d p r e s s b e a r i n g in-
to place.
HARLEY-DAVIDSON MOTOR CO.
Milwaukee 1. Wis.. U.S.A.