HOW TO REPLACE GEARS ON A HARLEY
You should provide the year of manufacture, but all five speed transmissions gear replacement access occurs throught the transmisson end cover.
1. before beginning, disconnect the positive battery lead, and tie down or block the bike for a sturdy working enviroment.
2. drain the oil from the drain plug screw located under the trans.
3. Next begin removing the right trans end cover, (the one that your clutch cable enters into), by unscrewing the 1/4" allen screws.
4. Next remove the trap door which is fastened with screws, and located between the trans end cover you just removed and the trans main case.
5. As you pull the trap door away, 2 shafts with splined sliding gears will still be attached to the trap door via a nut on each shaft, located on the outside of the trap door ball bearings. There is usually no need to remove these shafts, unless they are damaged, and you can inspect them without removal. Both the mainshaft and the countershaft will extract all the transmission gears except for the main drive gear - which is the gear that protudes out the left side of the trans, and had the rear belt drive pully attached. his gear usually doesn't need to be removed for most cause of transmission repair, which is 2nd or 3rd gear problems -Won't stay in gear - jumping out under a load or quick shifts.
6. Inspect the clutch gears for rounded shifter dogs - these are the square slotted teeth or dogs on the male side of the clutch gear, and the same shaped slots in the female side of the gear to recieve the dog. If any dogs or slots do not have a squre corner, replace them. 1st/2nd and 3rd/4th shifter clutch gears are interchangable. Also inspect the same dogs and slots on the other mating trans gears, replace if questionable.
7. also inspect the shifter forks for wear grooves at contact point, where they fit in the groove around the shifter cltch gears. Replace if questionable.8. Assembly is the reverse of disassembly.
8. Be sure to fill the transmission with 3/4 of a quart of oil, before you put the trans back into service.
I too do not have the right manuals for reference. Also, please include year and model
Sorry, I have no manuals on Harley's to reference.
SOURCE: reinstalling oil pump and cams on a 2003 Harley Davidson FLSTC
Absolutely!!! Have you replaced the stock cams with gear driven cams? On almost all cams there are "dots" or "circles" to mark where the cams should be. Additionally if using gear driven cams depending on who makes them there may some additional installation considerations, grinding for clearance, etc.
Also refer to the cam documention on piston position when installing. Hope this helps.
JP
SOURCE: harley 2012 FLHTK replacement transmission
You can buy the entire transmission as an assembly, just the gearset, or any individual parts.
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