Specifications

DESCRIPTION

CLUTCH

Type Dry-multiple disc

Capacity 206 ft-lbs torque

Spring pressure (total) 315 lbs.

Spring adjustment 1-1/32 in. from spring collar edge to outer disc surface.

CHAIN

Looseness 1/2 to 15/16 in. slack (cold engine)

MAINSHAFT MAIN DRIVE GEAR

Drive gear end play 0.0025 - 0.0135 in.

Bushing on mainshaft 0.0018-0.0032 loose

MAINSHAFT

Low gear end bearing

In housing 0.0013 in. loose - 0.0001 in. press

Housing in case 0.0005 in. loose - 0.0010 in press

Third gear

Bushing in gear Press fit

COUNTERSHAFT

Drive gear end bearing 0.0005 - 0.0019 in. loose

Low gear end bearing 0.0005 - 0.0019 in. loose

Second gear

Bushing on shaft 0.000 - 0.0015 in. loose

Bushing in gear 0.0005 - 0.0025 in. loose

Low gear

Bushing on shaft 0.000 - 0.0015 in. loose

Bushing in gear 0.0005 - 0.0025 in. loose

Shifter clutch

SHIFTER CAM End play

The transmission has four major assemblies: the clutch, gear box, gear shifter and starter. Each is a part of power transmission from engine to rear wheel or a means of power control.

CLUTCH

The clutch is made up of a drum or shell which is integral with the primary drive chain sprocket and which has inside a series of alternately positioned lined and unlined discs. The lined discs are doweled to the clutch hub which is keyed to the transmission shaft while the steel (unlined) discs are keyed to the clutch shell. When the clutch pressure plate is seated, a group of springs press the steel and lined discs together making a non-slipping connection between the engine and transmission.

GEAR BOX

The gear box contains a series of gears on a mainshaft and countershaft which may be powered in a selection of ratios according to speed and load requirements.

GEAR SHIFTER

The gear shifter is a unit mounted to the gear box which shifts the gear box components into desired ratios by means of shifting forks that slide gears into and out of mesh along shafts.

STARTER

Electric starter motor and Bendix type drive unit engages a ring gear on the clutch. The primary chain transmits the force through the front sprocket.

REPAIR PROCEDURE

When operating troubles develop in a transmission component, it is recommended procedure to first check the following adjustments.

1. Adjusting Clutch Control

2. Adjusting Clutch

3. Adjusting Shifter Linkage

4. Adjusting Shifter Cover d. 1

If the above adjustments do not correct trouble, disassemble and repair as described in repair sections. See "Locating Operating Troubles," Section 1, for aids to diagnosing trouble. It is not necessary to remove transmission from chassis to disassemble clutch, starter, transmission main-shaft, ball bearing, main drive gear oil seal or clutch release mechanism. However, extensive repairs are often easier and more quickly made if transmission unit is removed to bench as described in following section, "Stripping Motorcycle for Transmission Repair."

STRIPPING MOTORCYCLE FOR TRANSMISSION REPAIR

WARNING

Disconnect the battery cables (negative cable first) to avoid accidental start-up of the vehicle and possible personal injury.

1. Remove transmission drain plug and drain the oil from the case.

2. Remove foot shifter lever and cover plate. Remove chain housing cover. Remove compensating sprocket nut.

3. Remove clutch as described in "Disassembling Clutch.

4. Remove mainshaft key. Loosen the five 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. 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 guard, vent hose at T-connection 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 passenger footrest bracket. Remove starter motor bracket and pull starter motor out left side.

5. Disconnect clutch cable from clutch release arm.

6. Disconnect shifter release lever from transmission cover by removing nut and bolt.

7. Remove exhaust pipe.

8. On FL models, disconnect speedometer drive cable and housing from transmission.

9. Disconnect neutral Indicator switch wire clip.

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

11. Remove bolts and cap screws which secure transmission mounting plate to chassis.

12. Remove complete transmission with mounting pate.

Fill the transmission with 1 Vt pints of SAE 40 engine oil. Tighten the drain plug to 12-15 ft-lbs torque.

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.

IMPORTANT

After reassembly, chain housing must be airtight Check using Vacuum Gage Part No. 96950 68. Remove one of the four screws securing the front chain inspection cover and in its place screw in the threaded fitting of the gage. Then, with engine running check gage to see that there is a reading indicating 9-11 inches of water minimum. Perform check with vent hos€ from tee fitting to inner primary pinched closed with a pliers. The reading should now be 25 inches of water oi more. A lower reading indicates an air leak into chair housing either at gasket, solenoid, starter shaft, oi hoses.

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