Checking Adjustment Of Shifting Members

Checking Adjustment of Shifter Clutches and Sliding Gear

(To Identify Items, Refer to Illus. 121,122 and 123)

7. Check adjustment of shifter clutches and sliding gear with Harley-Davidson special gauge. Part No. 12074-39 (see Illus. 127 and 128). Complete instructions for checking and adjusting shifter clutches and sliding gear are included with gauge.

4 Speed Transmission: Shifter clutch (36) must be centered between gears (18) and (39), and shifter clutch (68) must be centered between gears (65) and (71). When centered as shown in Illus. 129 and 130, mainshaft shifter clutch (36) should have about .100" clearance, both sides. Countershaft shifter clutch (68) should have about .075" clearance, both sides.

3 Speed or 3 Speed-Reverse Transmission: Mainshaft shifter clutch (36) must be centered between gears (18) and (39). When centered as shown in Illus. 130, shifter clutch should have about .100" clearance, both sides. Sliding gear (65) must be spaced about .055" from mainshaft gear (41) with which it engages. When checking clearance, highest points of rounded ends of gear teeth must be in exact alignment.

After correct adjustment has been made, lock shifter fork shaft (98) in place with set screw (99). Be sure shifter finger rollers (94) and (102) are in place on shifter fork fingers.

Install gasket and cover assembly, registering slots in shifter cam over shifter finger rollers and install and tighten cover screws securely. Turn sprocket and shift through all gears as a further check that transmission is properly assembled.

Assembling and Installing Starter Assembly

(To Identify Items, Refer to Illus. 120)

8. Install release lever shaft (4) and release finger (6) in cover with plain washer (7) located between finger and bushing (8), and plain washer (9) on end of shaft and insert cotter pin (10).

To install starter crank bushihgs (22) and (24), press one bushing in from inner side of cover (25) so end of bushing will be just flush with bushing boss—press other bushing in from outer side of cover so end of bushing will be just flush with cover.

Install starter crank spring (19) and thrust washer (21) on starter crank and apply a film of light grease on oil seal (23) and on end of starter crank shaft before installing crank (18). With crank held in vise, wind spring by turning cover clockwise. Install starter crank gear (26) so dowel pin holds crank in normal (upward) position. Install lock washer (27) and nut (28) and tighten nut securely. Bend over one ear of nut lock washer against one side of nut. Install gasket over studs on right side of transmission case

Before starter cover is installed, clutch release bearing (12) must be inserted into cover, with slot in outer bearing race engaging clutch release finger (6) because starter crank gear (26) covers front edge of bearing as shown in Illus. 119. Insert push rod small diameter end into thrust bearing and insert the other end of push rod into mainshaft. With push rod serving as a pilot, move cover assembly into place, observing at the same time that groove in thrust bearing inner race <md ball plunger in starter clutch align so they will be engaged when assembly is completed. , . ,

Adjusting Shifter Cam Ball Plunger Spring Tension

(To Identify Items, Refer to Illus. 123)

In order to shift into different gear positions with minimum effort, and at same time making sure that shifter cam will remain locked in any gear position, it is essential that tension of shifter cam plunger spring (120) be correctly adjusted.

Spring tension will be correct when adjusting screw (119) is adjusted so distance from end of screw to shifter fork shaft (98) is 2-1/4".

Installing Clutch

9. Proceed with the assembly of clutch according to instructions under "Reassembling Clutch", Page 17. Adjust clutch as per instructions under "Adjusting Clutch Spring Tension," Page 16.

Before installing clutch hub, make sure tapered end (left end) of mainshaft and tapered hole in clutch hub are clean and free from oil or grease and key is in keyway in mainshaft.

1940 and Earlier Models: Clutch hub nut (9) Illus. 8, cannot be installed until after clutch is reassembled.

• 1941 to 1947 Models: Make sure clutch hub nut (12) is securely tightened, and one lip of lock washer (25) is bent up against one side of nut (see Illus. 9 and 137.)

All Models: Before installing clutch shell and sprocket, apply a few drops of oil or a very small amount of grease to ball bearing.

Installing Transmission in Chassis

Installation is a reverse procedure of removal. See "Removing Transmission from Chassis", Page 126.

After transmission has been installed, and transmission sub-mounting plate bolts and transmission mounting stud nuts have been securely tightened, check adjustment of chains, rear brake, clutch control and shifter control and adjust if needed.

CAUTION: Be sure transmission is filled to level of filler opening with oil of the same grade used in engine. See "Transmission Lubrication," Page 144,

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