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Shifter shaft bushing

Figure 4-12. Foot Shifter Cover - Exploded View

Figure 4-12. Foot Shifter Cover - Exploded View

Remove cotter pin (28) from end of shifter shaft. Remove shifter gear (28) and spring (30) from shaft and pull shaft (31) out of cover (32).

CLEANING. INSPECTION AND REPAIR (Figure 4-12)

Clean all parts except gaskets (8 and 17), and neutral indicator switch (18) in grease solvent. Clean switch with "Gunk" or solvent.

Inspect fit of shaft (31) in bushings (33 and 34). If there is considerable side play, replace bushings. Pawl carrier bushing (33) may be pressed out of carrier on arbor press. Shifter shaft bushing (34) is removed as follows: Thread 5/8 in. tap into bushing about 1/2 in. deep. Remove tap and heat shifter cover around bushing to about 300 degrees.

Quickly replace tap and clamp tap handle in vise. With rawhide mallet, tap cover near bushing until cover is driven off bushing. Insert new bushing with arbor press or soft metal hammer and wood block. Be sure bushing shoulder is seated against cover.

Inspect teeth on shifter gear and cam. Replace badly worn parts.

Inspect neutral indicator switch. Depress plunger in base of body. It should spring back without a bind. If panel light fails to light in neutral position, plunger is sticking. Switch cannot be repaired, it must be replaced. Do not test switch by passing current through it without having a neutral indicator panel light bulb in the circuit in series.

Inspect all springs. Inspect tips of cam follower (23) and shift pawls (10 and 11). If tips are rounded and worn, replace parts. To function properly these parts must have reasonably sharp tips.

Inspect all parts generally for cracks, bent parts and any wear that would impair intended functions. If hole in pawl carrier is elongated, bushing (33) must be replaced or mechanism will not shift properly.

ASSEMBLING SHIFTER COVER (FOOT SHIFT) (Figure 4-12)

It is necessary to time the shifter shaft (31) to the shifter gear (29), and the shifter gear to the cam gear on the shifter cam (27). If this is not done correctly, it will be impossible to shift into all gears.

Note position of the timing mark (Figure 4-13). This is the proper timing alignment.

Refer to Figure 4-12. Position shifter gear (29) and spring (30) in case, so side of gear with timing mark is toward case. Insert shifter shaft (31) so parts are timed as shown in Figure 4-13 and tap parts together. Insert cotter pin (28).

Install shifter cam (27) in cover so ground timing mark on top of a tooth or short tooth registers with timing mark on shifter gear. Slip oil seal (26) on the inner of two grooves on end of camshaft (25) and insert in cover, passing it through shifter cam. Secure shaft with lock screw (24).

Install cam follower (23), spring (22), retaining washer (21) and retainer (20). Install neutral indicator switch (18), washer (19) and check to make sure button on shifter gear contacts plunger in base of switch.

Position cover (32) in vise with shifter mechanism end upward. Place gasket (17) and adapter plate (16) over cover. Insert adapter plate bracket screw (14) and washer (15) in hole directly above end of shifter gear but do not tighten. Shift cam to any position but neutral. Rock cam back and forth to make sure spring loaded cam follower is seating exactly in one of the indexing notches, or "V's," that determine cam position for one of the four gears.

Rotate adapter plate until timing notch (Figure 4-14) in adapter plate, located at bottom of shifter gear hole, lines up with notch between two shifter gear teeth. Make alignment exact, then tighten adapter plate bracket screw (14).

Rotate shifter drum making sure that at each index point, timing notch on adapter plate aligns exactly between two shifter teeth. If alignment is correct, tighten screw(14) to 6-9 ft-lbs torque. If alignment is not correct, drum is not properly timed to shifter gear. Disassemble and align marks as explained above.

Apply "Grease-All" grease to curved springs (13) and insert them in slots on adapter plate. Grease ratchet end of shifter shaft. Lubricate pawls (10 and 11) with light oil after checking to see if they are free in holes in pawl carrier (9). Install pawl springs (12) and pawls in pawl carrier so notches in ends of pawls face inward or toward each other.

Install pawl carrier with pawls over end of shifter shaft with lug on pawl carrier inserted between ends of pawl carrier springs.

Lubricate back of pawl carrier with "Grease-All" grease and install cover gasket (8) and cover (7) so notches at top line up with corresponding notch on adapter plate. Apply Harley-Davidson "Stud and Bearing Mount," Part No. 99626-77, to threads of shorter screw (5) and insert through bottom hole. Secure with nut (6) on back of adapter plate. Apply "Stud and Bearing Mount" to threads of five long screws (4) and tighten all screws.

Position cover dust shield (3) over dowel pins on pawl carrier. Position shifter shaft lever (2) over dowel pins and secure with three shifter shaft lever screws (1). Also treat the threads of these screws with "Stud and Bearing Mount" before inserting.

Figure 4-14. Timing Shifter Notches

Figure 4-13. FLH Timing Shifter Gear

Figure 4-14. Timing Shifter Notches

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