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<font face="Andy" size="4">I recently purchased a '96 Road King transmission for an FXR I am building. Since the trans was an Ebay purchase, and going into basically a new build...I want to go thru it with a total rebuild. New gaskets, seals, and bearings. I am getting the cases powdercoated also so that it looks new again. I need to bore the swingarm pivot shaft hole larger to accept the updated '07 larger diameter pivot shaft and spherical bearings now used in Harley's FL series rubbermount bikes, instead of the old 5/8 shaft and swingarm cleveblocks....a much better system.
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">Hopefully this will explain a few procedures, and show just how simple the transmissions are. Basically all this would apply to 5 or 6 speeds, and right side drive or left. They are all assembled in the same manner with basically the same components. Normally this would be done in the bike, with the trans case still bolted in...but because I want this to look new, and bore the shaft out...I will be doing this on a bench. None of the basic rebuild actually requires pulling the transmission. This should also serve as a guide to anyone wanting to pull their 5 speed, and install a 6, as the techniques/tools will always be the same.</font></p>
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#2 shows the JIMS tool for pulling the inner primary race used with wet primaries.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans02.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#3 here the tool is slipped over the race, and the race is pulled from the mainshaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans03.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#4 here I am simply removing the transmission top, leaving the neutral indicator sensor installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans04.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#5 shows the trans top opened up, and I am removing the electronic speedo sensor.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans05.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#6 shows the view from the topside, most transmission problems can be diagnosed thru the top.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans06.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#9 shows a few parts accessible thru the clutch release cover. Also the ends of the main and countershafts and trap door bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans09.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#10 here we remove the bolts holding the shifter drum's pillar block bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans10.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#11 shows the trans after drum removal, and the three shifter forks. 2 mainshaft forks (pointing rearward) and 1 countershaft fork.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans11.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#12 shows that the drum's pillar block bearings simply slide off the drums ends.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans12.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#13 the shift fork shaft simply slides out. The shaft is also accessible from the other side of the trans, thru the allen plug.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans13.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#14 shows the transmission's 3 sliding gears, and the red lines point to the grooves in the same gears, where the forks ride on the edge of the gears, you can see the engagement dogs.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans14.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#15 removing the lock tabs for the main sprocket nut, threaded on the end of the shaft is the guide for the deep JIMS machine tool. Both the shaft's end and the main sprocket nut are LEFT HAND THREADS.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans15.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#16 removal of the nut, I can usually hold the pulley by hand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans16.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#17 remove the trap door's 5/16 and 1/4 inch bolts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans17.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#18 shows the spacer behind the shafts retaining nuts. Removal of these two nuts with a 1-1/16 socket. This step isn't usually done, but since I am replacing these bearings OUTSIDE of the transmission, I would just rather have them loose now. Many of these steps can be done in no particular order...and to pull the gear-set to install a 6 speed...you can just leave nuts alone, unless you are reusing your trap door.. right hand threads.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans18.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#19 shows me using that same JIMS machine guide as a thread protector, to knock out the gear-set. The clutch hub nut works fine for this also...just don't wanna bang up your shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans19.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#20 one or two smacks with a dead blow hammer and the trap door and gear-set slides off it's alignment roll pins.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans20.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#21 the gear-set can now be pulled out by hand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans21.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#22 using the dead blow, and a block of wood, with the pulley nut as a thread protector on the 5th gear, I knock 5th out of the main bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans22.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#23 using a seal puller.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans23.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#24 shows 3 things, removing the snap ring to pull the main drive bearing, loosening the jam nut on the shifter pawl adjusting screw, and removing the bolt holding the shifter arm on.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans24.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#25 after the arm is removed, the snap ring is pulled, and then the pawl assembly can be slid out of the case.
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#27 knocking out the main bearing. Pretty much just a slip fit in to the case...one or two taps and its out.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans27.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#32 the two halves draining. There are still a few oil fittings and drain plugs to remove, but basically we are there now. I need to set the top half in the mill to bore the pivot hole for the late model shaft...then off to the powdercoaters.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans32.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#33 clamping the trans case in the Bridgeport to locate the center of my shaft's bore.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans33.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#34 shows reaming the trans case after locating the hole, to accept the larger 3/4" pivot shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans34.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#35 in this picture, you can see the removed gear-set. Two sets of c-ring pliers (same tool used for evo exhaust retainers) and a simple rig to keep track of the transmissions disassembly order.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans35.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#36 is simply a close up of the 5-speed gear-set.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans36.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#37 shows the main drive gear slipped off the mainshaft, and flipped over onto the stand. This should keep each piece removed in order, so its basically just a matter of stacking the gears off, and back on when its time to reassemble. The photo also shows removal of the first retainer. Under each retainer will be a thrust washer.
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#39 shows the first split bearing, just open it up and slide it off. These have a plastic cage and are fairly delicate.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans39.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#40 removal of that same bearing.
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#42 just continue stacking them off.....and putting the gears on the stand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans42.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#43 finally down to the trap door, and removal of the main and countershafts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans43.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#44 shows the tool attached to press out the two shafts. This could also be done in a vertical press. </font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans44.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#45 shafts removed, the snap rings then come out....</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans45.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#46 with the trap door flipped over, just tap the bearings out.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans46.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#47 packing it all up, off to the powdercoaters.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans47.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#48 this is the kit I purchased for the rebuild. it will cover more years and models than just this trans, but hey gotta keep the gasket boards stocked, right?</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans48.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#51 pressing in the new bearings, numbers pointing out if there are any, and only applying pressure to the outer race to not damage the bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans51.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#53 here I am laying out most of the pieces I will need to stack this transmission back together. If its visible in the photo, the spacer slipped over the trap door end of the mainshaft has a small shoulder on it, up against the first spline. The countershaft spacer doesn't. It is flat...</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans53.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#54 on this particular gear it's easiest to install the snap ring first, then slide on the thrust washer and bearing, before installing into the trap door. The dogs on the side of the mainshaft 4th gear make removal/installation of that one retaining ring difficult. It can be done out of order...but its a bit of a pain. So then the inner races of the bearings are supported, and the shafts pressed into the trap door bearings....with that one gear installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans54.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#55 basically just continue to install your gears, pulling them off the stand, flipping them over and sliding them on. Bearings are lubricated with vaseline or assembly lube and carefully opened and slid over the shafts as you come to them. They tend to break if opened too far, so a bit of finesse is needed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans55.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#57 now we are down to the main drive gear which is a bit different from the other gears as the bearings are steel caged and pressed into the gear itself. So I have the gear supported in a small stand (piece of pipe) and am using a shaft to tap out the bearing on the far side.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans57.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#58 5th gear flipped over to remove the opposite bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans58.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#59 back under the press, to install the new bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans59.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#60 the seal is then installed...</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans60.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#61 and a completed gearset...ready to install into the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans61.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#62 here the coutershaft bearing is installed/pressed into the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans62.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#63 after pressing the main drive gear bearing in, I am going around the outer race to make sure it's fully seated.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans63.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#64 a new snap ring....beveled side out....</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans64.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#65 and a new shifter shaft seal installed flush with the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans65.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#66 shows the case then flipped over...and supported. 5th gear can then be reinstalled into the bearing.
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#67 flipped back over...this pic shows the Quad seal, drive spacer, and main seal.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans67.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#68 tapping the main seal in, I use a little clear silicone around the outer edge. seems a bit easier to install with the spacer still on the shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans68.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#69 shifter shaft and pawl lubed and slipped into the case from the inside. A washer and retaining snap ring is then installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans69.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#70 new gasket and the two roll pins installed into the case's trap door face. The case is then ready to have the gear-set reinstalled.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans70.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#71 the gear-set should slide right into your new counter shaft bearing and main drive gear.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans71.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#72 ready to tap onto the roll pins with a rubber mallet. You can see that I still haven't tightened the shaft keeper nuts, although they are loosely on the shafts with each having a spacer behind the nut. To me its easier to tighten these nuts once the trans is somewhat back together. again...alot of this can be done out of order...or in smaller groups for repair.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans72.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#73 shows the proper arrangement of the three shifter forks.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans73.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#74 with the forks in the grooves of the sliding gears...the shaft is installed thru the trap door. This could also be slid in thru the other side of the case depending on the job.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans74.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#75 installing the set screw at the other end of the shaft with a bit of teflon sealant. This should be installed until the shaft's end is flush with the face of the trap door.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans75.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#76 shifter pawl raised and the drum slipped into place. blue loctite for the retaining bolts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans76.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#77 shows installation of the pawl adjustment screw and jamb nut.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans77.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#78 is a close up attempting to show adjustment of the pawl with the trans in 3rd gear. Adjust the screw till the gap between the pawls and dowel pins on the drum have the same gap..</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans78.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#79 the oil pan gets a new gasket and is then bolted back on.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans79.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#82 a new gasket and the oil filler is reinstalled.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans82.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#83 a new throwout bearing and the oil slinger is installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans83.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#84 S&S high torque, no slip inner primary race is pressed onto the mainshaft. This race has a taper that lands on the shaft and is a pretty trick piece for any hi torque application as the stock races have a tendency to walk into 5th gear under loads.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans84.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#85 shows a newly rechromed late model clutch release cover bolted on, and the transmission basically cleaned up, sprayed with powdercoat protectant, and waiting to be put to use.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/medium/trans85.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#86 the trans fully installed and road tested, mated to a 124" motor, looks and shifts like new....and with a few new chrome bolts, not bad for a greasy $350.00 dollar Ebay purchase.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/medium/trans86.jpg width="500" height="449">
<p align="left"><img border="2" src="http://www.clubchopper.com/photopost/data/3557/transbanner.jpg" width="500" height="180"></p><table border="0" cellpadding="1">
<td valign="top" width="500" align="left" height="1">
<font face="Andy" size="4">I recently purchased a '96 Road King transmission for an FXR I am building. Since the trans was an Ebay purchase, and going into basically a new build...I want to go thru it with a total rebuild. New gaskets, seals, and bearings. I am getting the cases powdercoated also so that it looks new again. I need to bore the swingarm pivot shaft hole larger to accept the updated '07 larger diameter pivot shaft and spherical bearings now used in Harley's FL series rubbermount bikes, instead of the old 5/8 shaft and swingarm cleveblocks....a much better system.
</font></p>
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">Hopefully this will explain a few procedures, and show just how simple the transmissions are. Basically all this would apply to 5 or 6 speeds, and right side drive or left. They are all assembled in the same manner with basically the same components. Normally this would be done in the bike, with the trans case still bolted in...but because I want this to look new, and bore the shaft out...I will be doing this on a bench. None of the basic rebuild actually requires pulling the transmission. This should also serve as a guide to anyone wanting to pull their 5 speed, and install a 6, as the techniques/tools will always be the same.</font></p>
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#1 shows the basic Harley FLT transmission.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans01.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#2 shows the JIMS tool for pulling the inner primary race used with wet primaries.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans02.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#3 here the tool is slipped over the race, and the race is pulled from the mainshaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans03.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#4 here I am simply removing the transmission top, leaving the neutral indicator sensor installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans04.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#5 shows the trans top opened up, and I am removing the electronic speedo sensor.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans05.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#6 shows the view from the topside, most transmission problems can be diagnosed thru the top.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans06.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#7 shows removal of the oil filler snout.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans07.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#8 remove the screws holding the clutch release cover.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans08.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#9 shows a few parts accessible thru the clutch release cover. Also the ends of the main and countershafts and trap door bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans09.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#10 here we remove the bolts holding the shifter drum's pillar block bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans10.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#11 shows the trans after drum removal, and the three shifter forks. 2 mainshaft forks (pointing rearward) and 1 countershaft fork.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans11.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#12 shows that the drum's pillar block bearings simply slide off the drums ends.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans12.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#13 the shift fork shaft simply slides out. The shaft is also accessible from the other side of the trans, thru the allen plug.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans13.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#14 shows the transmission's 3 sliding gears, and the red lines point to the grooves in the same gears, where the forks ride on the edge of the gears, you can see the engagement dogs.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans14.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#15 removing the lock tabs for the main sprocket nut, threaded on the end of the shaft is the guide for the deep JIMS machine tool. Both the shaft's end and the main sprocket nut are LEFT HAND THREADS.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans15.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#16 removal of the nut, I can usually hold the pulley by hand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans16.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#17 remove the trap door's 5/16 and 1/4 inch bolts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans17.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#18 shows the spacer behind the shafts retaining nuts. Removal of these two nuts with a 1-1/16 socket. This step isn't usually done, but since I am replacing these bearings OUTSIDE of the transmission, I would just rather have them loose now. Many of these steps can be done in no particular order...and to pull the gear-set to install a 6 speed...you can just leave nuts alone, unless you are reusing your trap door.. right hand threads.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans18.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#19 shows me using that same JIMS machine guide as a thread protector, to knock out the gear-set. The clutch hub nut works fine for this also...just don't wanna bang up your shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans19.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#20 one or two smacks with a dead blow hammer and the trap door and gear-set slides off it's alignment roll pins.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans20.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#21 the gear-set can now be pulled out by hand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans21.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#22 using the dead blow, and a block of wood, with the pulley nut as a thread protector on the 5th gear, I knock 5th out of the main bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans22.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#23 using a seal puller.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans23.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#24 shows 3 things, removing the snap ring to pull the main drive bearing, loosening the jam nut on the shifter pawl adjusting screw, and removing the bolt holding the shifter arm on.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans24.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#25 after the arm is removed, the snap ring is pulled, and then the pawl assembly can be slid out of the case.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans25.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#26 removing the pawl adjuster screw.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans26.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#27 knocking out the main bearing. Pretty much just a slip fit in to the case...one or two taps and its out.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans27.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#28 removing the oil pan bolts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans28.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#29 oil pan removed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans29.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#30 pulling the shifter shaft seal.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans30.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#31 knocking out the countershaft bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans31.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#32 the two halves draining. There are still a few oil fittings and drain plugs to remove, but basically we are there now. I need to set the top half in the mill to bore the pivot hole for the late model shaft...then off to the powdercoaters.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans32.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#33 clamping the trans case in the Bridgeport to locate the center of my shaft's bore.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans33.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#34 shows reaming the trans case after locating the hole, to accept the larger 3/4" pivot shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans34.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#35 in this picture, you can see the removed gear-set. Two sets of c-ring pliers (same tool used for evo exhaust retainers) and a simple rig to keep track of the transmissions disassembly order.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans35.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#36 is simply a close up of the 5-speed gear-set.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans36.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#37 shows the main drive gear slipped off the mainshaft, and flipped over onto the stand. This should keep each piece removed in order, so its basically just a matter of stacking the gears off, and back on when its time to reassemble. The photo also shows removal of the first retainer. Under each retainer will be a thrust washer.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans37.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#38 further removal of gears.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans38.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#39 shows the first split bearing, just open it up and slide it off. These have a plastic cage and are fairly delicate.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans39.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#40 removal of that same bearing.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans40.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#41 a close up.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans41.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#42 just continue stacking them off.....and putting the gears on the stand.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans42.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#43 finally down to the trap door, and removal of the main and countershafts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans43.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#44 shows the tool attached to press out the two shafts. This could also be done in a vertical press. </font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans44.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#45 shafts removed, the snap rings then come out....</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans45.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#46 with the trap door flipped over, just tap the bearings out.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans46.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#47 packing it all up, off to the powdercoaters.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans47.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#48 this is the kit I purchased for the rebuild. it will cover more years and models than just this trans, but hey gotta keep the gasket boards stocked, right?</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans48.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#49 contents of the JIMS kit.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans49.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#50 shows the powdercoated trap door, ready for assembly.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans50.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#51 pressing in the new bearings, numbers pointing out if there are any, and only applying pressure to the outer race to not damage the bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans51.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#52 new snap rings installed...
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans52.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#53 here I am laying out most of the pieces I will need to stack this transmission back together. If its visible in the photo, the spacer slipped over the trap door end of the mainshaft has a small shoulder on it, up against the first spline. The countershaft spacer doesn't. It is flat...</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans53.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#54 on this particular gear it's easiest to install the snap ring first, then slide on the thrust washer and bearing, before installing into the trap door. The dogs on the side of the mainshaft 4th gear make removal/installation of that one retaining ring difficult. It can be done out of order...but its a bit of a pain. So then the inner races of the bearings are supported, and the shafts pressed into the trap door bearings....with that one gear installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans54.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#55 basically just continue to install your gears, pulling them off the stand, flipping them over and sliding them on. Bearings are lubricated with vaseline or assembly lube and carefully opened and slid over the shafts as you come to them. They tend to break if opened too far, so a bit of finesse is needed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans55.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">##56 continue to install gears/rings/thrust washers.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans56.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#57 now we are down to the main drive gear which is a bit different from the other gears as the bearings are steel caged and pressed into the gear itself. So I have the gear supported in a small stand (piece of pipe) and am using a shaft to tap out the bearing on the far side.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans57.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#58 5th gear flipped over to remove the opposite bearing.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans58.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#59 back under the press, to install the new bearings.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans59.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#60 the seal is then installed...</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans60.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#61 and a completed gearset...ready to install into the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans61.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#62 here the coutershaft bearing is installed/pressed into the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans62.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#63 after pressing the main drive gear bearing in, I am going around the outer race to make sure it's fully seated.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans63.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#64 a new snap ring....beveled side out....</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans64.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#65 and a new shifter shaft seal installed flush with the case.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans65.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#66 shows the case then flipped over...and supported. 5th gear can then be reinstalled into the bearing.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans66.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#67 flipped back over...this pic shows the Quad seal, drive spacer, and main seal.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans67.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#68 tapping the main seal in, I use a little clear silicone around the outer edge. seems a bit easier to install with the spacer still on the shaft.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans68.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#69 shifter shaft and pawl lubed and slipped into the case from the inside. A washer and retaining snap ring is then installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans69.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#70 new gasket and the two roll pins installed into the case's trap door face. The case is then ready to have the gear-set reinstalled.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans70.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#71 the gear-set should slide right into your new counter shaft bearing and main drive gear.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans71.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#72 ready to tap onto the roll pins with a rubber mallet. You can see that I still haven't tightened the shaft keeper nuts, although they are loosely on the shafts with each having a spacer behind the nut. To me its easier to tighten these nuts once the trans is somewhat back together. again...alot of this can be done out of order...or in smaller groups for repair.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans72.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#73 shows the proper arrangement of the three shifter forks.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans73.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#74 with the forks in the grooves of the sliding gears...the shaft is installed thru the trap door. This could also be slid in thru the other side of the case depending on the job.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans74.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#75 installing the set screw at the other end of the shaft with a bit of teflon sealant. This should be installed until the shaft's end is flush with the face of the trap door.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans75.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#76 shifter pawl raised and the drum slipped into place. blue loctite for the retaining bolts.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans76.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#77 shows installation of the pawl adjustment screw and jamb nut.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans77.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#78 is a close up attempting to show adjustment of the pawl with the trans in 3rd gear. Adjust the screw till the gap between the pawls and dowel pins on the drum have the same gap..</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans78.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#79 the oil pan gets a new gasket and is then bolted back on.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans79.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#80 speedo sensor.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans80.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#81 a new top.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans81.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#82 a new gasket and the oil filler is reinstalled.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans82.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#83 a new throwout bearing and the oil slinger is installed.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans83.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#84 S&S high torque, no slip inner primary race is pressed onto the mainshaft. This race has a taper that lands on the shaft and is a pretty trick piece for any hi torque application as the stock races have a tendency to walk into 5th gear under loads.</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans84.jpg width="500" height="449">
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<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#85 shows a newly rechromed late model clutch release cover bolted on, and the transmission basically cleaned up, sprayed with powdercoat protectant, and waiting to be put to use.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/medium/trans85.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">#86 the trans fully installed and road tested, mated to a 124" motor, looks and shifts like new....and with a few new chrome bolts, not bad for a greasy $350.00 dollar Ebay purchase.
</font></p><table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/medium/trans86.jpg width="500" height="449">
<table border="0" cellpadding="1"><td valign="top" width="500" align="middle" height="1"><img border="2" src=http://www.clubchopper.com/photopost/data/3557/trans87.jpg width="500" height="650">
<table border="0" cellpadding="1"><td valign="top" width="500" align="left" height="1"><font face="Andy" size="4">TRANSMISSION TORQUE SPECS
5/16: TRAP DOOR BOLTS 13-16 FT LBS
1/4 : TRAP DOOR, CLUTCH RELEASE COVER, TOP 7-9 FT LBS
NEUTRAL SWITCH: 3-5 FT LBS
TRANS CASE TO FRAME(SOFTAIL): 30-33 FT LBS
SHIFTER DRUM SUPPORT BLOCK BOLTS: 7-9 FT LBS
MAIN AND COUNTERSHAFT TRAP DOOR NUTS: 45-55 FT LBS
CLUTCH HUB NUT: 70-80 FT LBS
TRANS SPROCKET NUT: 50 FT LBS THEN 30 DEGREES- 45 DEGREES ADDITIONAL
SPROCKET NUT LOCK SCREWS: 7-9 FT LBS
Exploded view and oem part numbers. (http://www.customchrome.com/catalogs/ccp2008/t1.asp?Page=604)
</font></p>
<p align="center">
<font face="Andy" size="4">GC</font></p>
<p align="center">
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