Stripping Motorcycle For Transmission Repair

1. Remove battery ground wire and battery. Remove foot shifter lever and cover plate. Remove chain housing cover. Remove compensating sprocket nut.

2. Remove clutch as described in "Disassembling Clutch."

3. Remove mainshatt key. Loosen the tive transmission base mounting nuts. Remove the four bolts attaching chain housing to engine crankcase and four bolts attaching housing to transmission. Remove the two chain housing stud nuts attaching starter housing to chain guard. Remove wires connected to starter solenoid terminals. Pull inner chain housing loose from mainshaft using Puller, Part No. 95960-41 A, which has four screws to fit tapped holes in chain housing. Care must be taken to be sure housing moves out squarely as front end is snug fit on shoulder of crankcase. As housing is pulled out, shake starter assembly shaft to free it from gear in starter motor housing. Remove chain oiler hose at oil pump. Remove chain housing oil return hose at rear of chain quard and vent host at T-con-nection and move housing away. On FX, remove foot shifter lever linkage from chain housing and shifter pawl lever on transmission cover. Remove battery carrier bracket from right side of transmission. Remove right Buddy Seat foot-rest bracket. Remove starter motor bracket and pull starter motor out left side.

4. Disconnect clutch cable from clutch release arm.

5. Disconnect shifter rod from transmission cover by removing nut and bolt or cotter pin and clevis pin.

6. Remove exhaust pipe.

7. Disconnect speedometer drive cable and housing from transmission. Disconnect neutral indicator switch wire clip.

8. Remove rear chain connecting link and chain. Remove bolt which secures transmission to support bracket on right side of frame.

9. Hemove bolts and cap screws, which secure transmission mounting plate to chassis.

10. Remove complete transmission with mounting plate.

Reassembly is the reverse of disassembly with the following exceptions:

The four nuts securing the transmission to mounting plate as well as the bolt which secures transmission to frame support bracket should be left loose to facilitate easy alignment of the chain housing with engine crankcase and transmission bolts.

Primary chain case bolts on engine and transmission should be tightened evenly to 18 to 22 ft-lbs torque so housing does not bind on transmission mainshaft or shoulder on engine crankcase. Final tightening should start at three bolts at engine crankcase, then four bolts at transmission then four base mounting nuts and bolts securing transmission to chassis bracket.

DIY Battery Repair

DIY Battery Repair

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