Transmission Case

DISASSEMBLING

Remove transmission from chassis as described in "Strip ping Motorcycle for Transmission Repair."

Remove shifter cover. Slide shifter forks together so thai two gears engage, locking transmission. Remove kick starter clutch as described under "Kick Starter." If main drive gear is to be removed from transmission, remove rear chain sprocket nut (left hand thread) and sprocket while transmission is locked. Remove shifter forks as described under "Removing Shifter Forks."

DISASSEMBLING COUNTERSHAFT (Figure 4-19)

For 1978-1979 models bend tabs on lockwasher (2) flat. Remove countershaft nut (1), lockwasher (2), and lock plate (3). On 1980 models, remove retaining plate (3A). Tap countershaft (4, 4A) out just far enough so that countershaft washer (6) may be lifted out with a piece of stiff wire shaped like a hook. Push countershaft the rest of the way out. Remove countershaft gear cluster. Slide low gear (7), bearing washer (9) and shifter clutch (10) off countershaft gear (15). Remove retaining ring (11), washer (13) and gear (13).

On FL models, remove speedometer drive housing screw (16) and washer (17) and lift out speedometer drive unit (18) and gasket (19) from gear case.

DISASSEMBLING MAINSHAFT (Figure 4-20)

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

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 assembly (9) and bearing race (7) out right side of case, slipping third gear (10), retaining washer (11), lock ring (12) and shifter clutch (13) off left end of mainshaft and out through shifter cover opening in case.

Disassemble the mainshaft gear (8) and ball bearing (6) assembly 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 with 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 4-21)

When removing main drive gear with transmission assembled, lock transmission by engaging two gears at

4-19

1.

Countershaft nut (1978-1979)

10.

Shifter clutch

20.

Needle bearing (2)

2.

Lockwasher (1978-1979)

11.

Retaining ring

21.

Countershaft mounting collar

3.

Retaining plate (1978-1979)

12.

Gear retaining washer

(starter side)

3A. Retaining plate (1980)

13.

Countershaft second gear

22.

Countershaft mounting collar

4.

Countershaft (1978-1979)

14.

Second gear bushing

(starter side)

4A.

Countershaft (1980)

15.

Countershaft gear

23.

Side cover nut and washer (9)

5.

O-ring

16.

Speedometer drive housing

24.

Side cover

6.

End play washer (variable)

screw (FL models)

25.

Side cover gasket

7.

Low gear

17.

Washer (FL models)

26.

Side cover upper bushing

8.

Low gear bushing

18.

Speedometer drive unit

27.

Side cover lower bushing

9.

Low gear bushing washer

Drive unit gasket (FL models)

Figure 4-19. Countershaft and Case Assembly — Exploded View

Figure 4-19. Countershaft and Case Assembly — Exploded View once, then bend ear of lockwasher away from nut. Remove the nut (nut is left-hand thread) using Sprocket Nut Wrench, Part No. 94660-37.

When removing main drive gear with the transmission already disassembled, position transmission case in a vise. Position the chain on sprocket teeth and nail each end of the chain to the bench to prevent sprocket from turning.

Bend ear of lockwasher away from flat of nut and remove sprocket locknut (1) and washer (2) with Sprocket Locknut Wrench, Part No. 94660-37.

Figure 4-20. Mainshaft Assembly — Exploded View

1.

Bearing housing retaining

4.

Ball bearing nut

plate screw (4)

5.

Lockwasher

2.

Oil deflector (kickstart models)

6.

Mainshaft bearing

3.

Retaining plate (1978-1979)

7.

Mainshaft bearing race

3A.

Retaining plate (1980)

8.

Low and second gear

Mainshaft Third gear Retaining washer Lock ring Shifter clutch Third gear bushing

Remove sprocket (3) from gear. Push main drive gear (4) into case and withdraw it from top.

Remove main drive gear oil seal (7) and main drive gear spacer (8).

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, bearings and shafts. If bent or worn, install new parts. If mainshaft ball bearing (6, figure 4-20) is worn to point where play is obviously too great, install new bearing.

If main drive gear (4, Figure 4-21) fit is excessively loose on mainshaft, replace bushing (10) and ream to 1.002 to 1.003 in. diameter to provide specified fit on mainshaft using a 1 inch dia. expansion reamer (See TRANSMISSION SPECIFICATIONS).

Oil seals (5 and 7) 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. diameter thinwall tubing using mainshaft as a pilot. Before installing, apply a coat of Harley-Davidson "Retaining Compound," Part No. 99628-79, in recess to prevent any oil leakage.

Carefully check shifter clutches (10, Figure 4-19 and 13, Figure 4-20) 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 (6, Figure 4-21, 6, Figure 4-20 and 20, Figure 4-19).

ASSEMBLING MAIN DRIVE GEAR

See Figure 4-21. Press needle bearing (6) into case using a suitable drift. Press on lettered side of bearing only. Press flush with outside of case. Install main drive gear (4) from inside case. Coat rollers lightly with grease. Install main drive gear spacer (8) in oil seal (7) and press in oil seal flush with case. Sprocket (3) may be assembled after mainshaft and countershaft are installed. 1978-1979 sprockets have a recess on one side which is installed towards the transmission case. 1980 sprockets are flat on both sides and can be installed either way.

ASSEMBLING MAINSHAFT

See Figure 4-20. Assemble parts 4 through 8 to main-shaft before installing mainshaft in gear case. Position gear (8) on shaft splines. Press or tit ball bearing housing (7) over ball bearing (6) and press onto shaft. Assemble lockwasher (5) and nut (4) to shaft and tighten to 50 to 60 ft-lbs torque. Bend over one ear of lockwasher against flat of nut.

Insert mainshaft assembly Into transmission case far enough to install gear (10) washer (11), lock ring (12) and shifter clutch (13) over shaft. Always install new lock rings and make sure they are properly seated in lock ring groove. One side of mainshaft shifter clutch is stamped "HIGH." Make sure this side faces main drive gear.

With a suitable tool, work lock ring onto shaft splines. Use tool wedged against shifter clutch to force lock ring into seat in shaft. Use care not to distort lock ring.

With a soft metal hammer or brass drift, tap mainshaft assembly into case until flange on ball bearing housing is shouldered against case. On 1978-1979 models, install retaining plate (3), oil deflector (2) and four screws (1). Tighten screws to 6 to 9 ft-lbs torque. On 1980 models, do not install plate (3A) until countershaft is installed.

ASSEMBLING COUNTERSHAFT (Figure 4-19)

Before installing countershaft gear train to shaft and case, it is necessary to check bearing fit and shaft end play.

If countershaft mounting collars (21 and 22) were removed for replacement, press or drive old parts out and new parts in after gear case has been heated to approximately 300 degrees to expand case and facilitate pressing.

Install needle bearings (20) in countershaft gear (15). Coat bearing rollers with grease.

Install countershaft gear in case holding end play adjusting washer (6) in place with daub of heavy grease. Install countershaft.

Check end play with feeler gauge between end play adjusting washer and bushing in case end of countershaft gear. Consult transmission specifications for tolerances. Increase or decrease end play as necessary by fitting end play washer (6) of required thickness. Washers are available in thicknesses of 0.074, 0.078,0.082,0.085, 0.090, 0.095 and 0.100 in. When correct gear end play has been established, remove countershaft and gear from case. Set aside adjusting washer until needed for assembly.

Install gear bushing (14), gear (13), thrust washer (12) and retaining ring (11) on countershaft gear (15).

Install shifter clutch (10), thrust washer (9), gear bushing (8), and gear (7) on countershaft gear (15).

Place end play washer (6) on end of countershaft gear, holding in position with daub of grease. Position assembly in transmission case and insert countershaft (4, 4A) with O-ring (5).

On 1978-1979 models, install the countershaft retaining plate (3), lockwasher (2) and nut (1). The flat side of the retaining plate should fit against the mainshaft bearing retaining plate (3, Figure 4-20). Tighten the nut to 55-60 ft-lbs torque and bend one ear of lockwasher against nut flat.

On 1980 models, install the mainshaft bearing retaining plate (3A) so the ear fits into groove on end of countershaft. Secure the plate with the four screws.

On FL models, install gasket (19), drive unit (18), washer (17) and screw (16).

Install shifter forks as described under "Assembling Shifter Forks" and check spacing. Slide shifter forks together to lock transmission and install sprocket (if not on) lockwasher and nut. Tighten nut to 140 to 150 ft-lbs torque and bend tab on lockwasher against flat on nut. Install starter clutch and check shifter spacing. Install

1. Sprocket locknut

2. Sprocket lockwasher

3. Chain sprocket

4. Main drive gear

5. Main drive gear shaft seal

6. Needle bearing

7. Main drive gear oil seal

8. Main drive gear spacer

9. Transmission case

10. Main drive gear bushing

Figure 4-21. Main Drive Gear — Exploded View sitae cover ana sniner cover, insiau an aDOve items as described in pertinent sections.

Assemble transmission to motorcycle and connect control: in reverse order of stripping procedure described in "Strip ping Motorcycle for Transmission Repair."

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TOOLS

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