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Figure 4-18. Countershaft and Case Assembly - Exploded View i

Remove spring lock ring (14), gear retaining washer (lb), countershaft second gear (16) and second gear bushing (17).

Remove the bearings (18 or 18A) and lock ring (20).

Remove roller thrust washer (21), bearings (22 or 22A), retaining washer (23) and lock ring (24) from opposite end of countershaft gear (25).

CAUTION — On early 1976 and earlier models, when disassembling countershaft assembly, be sure all rollers (18 or 22) are accounted for and roller set from each end of gear is wrapped separately in paper or cloth. Mark each roller set for end of gear from which it was removed. If any of the rollers are lost or if sets become mixed, both sets will have to be replaced with new parts even though in serviceable condition.

Remove speedometer drive housing screw (26) and washer (27) and lift out speedometer drive unit (28) and gasket (29) from gear case.

DISASSEMBLING MAINSHAFT (Figure 4-19)

Remove the four bearing housing retaining plate screws (1), oil deflector (2) and retaining plate (3).

Drive mainshaft assembly toward right side of case with rawhide mallet or block of wood and hammer until main-shaft third gear (10) contacts boss in bottom of case. With screwdriver or other suitable tool, pry lock ring (12) out of groove in mainshaft and slide it onto mainshaft splines. Drive mainshaft (9) out right side of case, slipping third gear (10), retaining washer (11), spring lock ring (12) and shifter clutch (13) off left end of mainshaft and out through shifter cover opening in case.

Disassemble the mainshatt gear ana Dan oearing assemDiy only if inspection shows a need for replacing worn or damaged parts.

Clamp mainshaft in copper-faced vise jaws. Bend ear of lockwasher (5) away from flat of nut (4) and remove nut and washer. Bearing (6) and gear (8) may then be removed win the All Purpose Claw Puller, Part No. 95635-46 or an arbor press. If using claw puller, insert center Adapter. Part No 95636-46 into end of shaft to prevent damage to shaft Bearing and gear are removed separately.

DISASSEMBLING MAIN DRIVE GEAR (Figure 4-20)

Position gear box in vise and nail or bolt length of rear chain to bench. Engage chain on sprocket teeth to keep sprocket from turning.

Bend ear of lockwasher away from flat of nut and remove sprocket locknut (1) and washer (2) with special Wrench, Part No. 94660-37. Nut has left hand thread. Remove sprocket (3)fromgear. Push main drive gear (4) into case and withdraw it from top. Thrust washer (6) usually comes out with gear. Remove the 44 roller bearings (7) or needle bearings (7A). Be sure all rollers are accounted for and wrap them in paper or cloth. If any of these rollers are lost or if rollers from another bearing become mixed with them, the entire set must be discarded and a new set fined, even though the old rollers are in serviceable condition.

Remove main drive gear oil seal (8) and main drive gear spacer (10).

1. Bearing housing retaining plate screw (4)

2. Oil deflector

3. Retaining plate

4. Ball bearing nut

5. Ball bearing washer

6. Mainshaft bearing

7. Mainshaft bearing housing

8. Low and second gear 8A. Low and reverse gear

(handshift)

9. Mainshaft

10. Third gear

10A. Mainshaft second gear (handshift)

11. Retaining washer

12. Lock ring

13. Shifter clutch

14. Third gear bushing

CLEANING, INSPECTION AND REPAIR

Clean all parts except gaskets (all gaskets should be replaced) with cleaning solvent and blow dry with compressed air

Inspect all gears. If teeth are pitted, scored, cracked, chipped or if case hardening is worn through, replace with new gears. Replace sprocket if worn.

Inspect all bushings, bearing races and shafts. If bent or worn, install new parts. If mainshaft ball bearing (6, Figure 4-19) is worn to point where play is obviously too great, install new bearing.

To install main drive gear bearing race (13, Figure 4-20), heat case to about 300 degrees and press out old race with arbor press after removing bearing race retaining ring (12). Reheat case and press in new race until flange is seated against case. Install new bearing race retaining ring.

Oil seal (5), cork washer (9) and oil seal (8) should not be reinstalled if they have been removed. An oil leak will probably develop. Use new parts.

Press new mainshaft seal (5) into drive gear recess, use a piece of 1 in. dia. thin wall tubing using mainshaft as a pilot. Before installing, apply a coat of Harley-Davidson "Retaining Compound," Part No. 99628-77 in recess to prevent any oil leakage.

Carefully check shifter clutches (13, Figures 4-18 and 4-19) and engaging dogs on gears. If they are rounded or battered appearing, they must be replaced.

Worn shifter clutch and gear dogs result from shifting abuses or from out-of-adjustment clutch that does not release fully. Damaged engaging dogs try to creep out of engagement under a steady load. This creeping action develops great side pressure that results in damage to shifting mechanism and all thrust points along shaft assemblies.

Check bearings (7 and 7A, Figure 4-20 and 18,18A, 22 and 22A, Figure 4-18) for proper fit in races according to tolerances shown in 'Transmission Specifications." Replacement rollers are available standard, .0004 in. and .0008 in. oversize.

ASSEMBLING MAIN DRIVE GEAR (Figure 4-20)

Assuming that main drive gear oil seal (8), oil seal cork washer (9) and gear spacer (10) are assembled in case (replacing these parts must be done before gear box is disassembled or after it is repaired and assembled as described in "Installing Oil Seal"), install rollers (7) in bearing outer race (13), holding rollers in place with a light coat of grease, or install needle bearing (7A).

On early 1977 and earlier models, install main drive gear thrust washer (6) on main drive gear. Insert main drive gear (4) into gear box. Be sure rollers stay in place as gear is inserted. Install main drive gear spacer key (11), registering longer section of key in any splineway on main drive gear and shorter section of key in outer edge of main drive gear spacer.

On late 1977 and later models, press needle bearing (7A) into case. Press on lettered side of bearing only and install bearing flush with the case.

Install sprocket (3) with flat side outward. Install lock-washer (2) and sprocket locknut (1). Hold sprocket as outlined in disassembly procedure and tighten nut to 140-150 ft-lbs torque with Wrench, Part No. 94660-37. On 1974 and later FX models, assemble the sprocket after countershaft and shifter forks are assembled. Check main drive gear assembly end play. See "Transmission Specifications" for proper tolerances. Bend one ear of lockwasher against flat of nut.

1. Sprocket locknut

2. Sprocket lockwasher

3. Chain sprocket

4. Main drive gear

5. Main drive gear shaft seal

6. Thrust washer*

7. Roller bearings (44) (early 1977 and earlier)

7A. Needle bearing

(late 1977 and later)

8. Main drive gear oil seal

9. Oil seal cork washer (early 1977 and earlier)

10. Main drive gear spacer

11. Main drive gear spacer key (early 1977 and earlier)

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