Question about Harley Davidson XLH 1000 Sportster Motorcycles

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How to install kickstart case cover and gear assembly on 69 flh 4 speed ratchet top transmision

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If all you want to do is install a the kick start case cover, drain the transmision fluid and just take the old one off along with the kicker lever intact. You'll need to look inside and see the relationship of the kicker gear stop and the kick starter lever. Then, once you see how it's supposed to look, ie. the kicker straight up and the kicker gear stop at the X o'clock positon, start taking the stuff apart. Transfer all the old parts to the new kicker cover. Align the kicker gear properly with the kicker lever. When you install the old shaft into the new cover, make sure you put a new seal in between the two bushings so it doesn't leak. Put the new cover with the rest of the kicker parts in it back on the transmission and refill the transmission with lube. 20-24 ounces.

If the clutch gear on the end of the mainshaft needs to be replaced, it's advisable to have the special puller to get it off with. If you don't have the puller, you can put some pressure on the clutch gear like you're trying to pry it off and rap on it with a hammer. Hit the side of the gear not the end of the shaft. Don't hit it hard enough to break anything, just a good tap should pop it off. If not, you'll have to find someone with a puller or buy one.

good Luck
steve

Posted on Oct 01, 2010

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My 2005 Pontiac Bonneville GXP will not shift into 4th gear I was to it was a fourth gear band but is that the only problem that will cause itI'notto shift into 4th gear


Which transmission does yours have 4T65-E or 4T80-E ?

4T80-E
No Fourth Gear

Checks

Causes

1-2 Shift Solenoid Valve
?€¢
Inoperative
?€¢
Debris
?€¢
Pinched wires

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Misassembled

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Burned, slipping, missing

4th Servo Cover

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Broken, seized

4th Servo Piston

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4th Servo Seals

Rolled, cut or damaged
4T65-E
Slipping or No Fourth Gear
Slipping or No Fourth Gear Checks
Cause

DEFINITION: A large engine RPM increase is noted in fourth gear, Drive range, with little or no vehicle forward speed increase. First, second, and third gear operation are normal. Shifts into fourth gear are soft or do not occur. Fourth gear ratio is 0.705:1.

Automatic Transmission Fluid Level
Low fluid level

Transmission Main Line Pressure
Low transmission main line pressure

Oil Filter Assembly
• The oil filter assembly (100) is missing, plugged, or damaged.
• The oil filter seal assembly (101) is missing or is damaged.

Control Valve Body Assembly
• The 3-4 shift valve (362) or the 4-3 manual downshift valve (360) is stuck or binding.
• Debris is found in the passages of the control valve body (301) or of the control valve body spacer plate and gasket assembly (396)

Case Cover Assembly
Distortion or damage occurs at the manual valve (404) or at the case cover (401), causing PRN oil leak.

Driven Sprocket Support Assembly
A plugged third clutch oil passage in the driven sprocket support assembly (609)

Fourth Clutch Assembly
• The clutch plates (500-502) are worn, damaged, or misassembled.
• A missing or not seated fourth clutch spring retaining ring (601)
• A damaged spring assembly (602) or piston (603)
• Worn or damaged fourth clutch piston seals (604, 605)

Third Clutch Sprag Assembly
• The sprag (720) was misassembled or backwards on the inner race (661).
• A damaged third clutch sprag assembly (653, 661, 719-721)

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1 Answer

What turns the speed sensor in tranny 2004 isuzu.rodeo 3.5 Can it be repaired without replacing the transmision?


it is driven by a drive gear on the output shaft of the transmission. you could have a bad driven gear that is the gear that is driven to create the electrical pulses to show a speed. the drive gear on some transmissions are part of the output shaft and some gears are replaceable without replacing the output shaft. in either case a part can be replaced without replacing the complete transmission.

Sep 29, 2014 | 2004 Isuzu Rodeo

1 Answer

I have an 87 ford f 250 with a 4 speed manual transmision it will not shift into any gear


PULL UP CARPET AND REMOVE PANEL TO ACCESS THE TOP OF TRANNY.PULL TOP OF TRANNY OFF AND FIND AND REPLACE BROKEN PARTS!!

Dec 14, 2011 | Transmission & Drivetrain for Ford Transit...

1 Answer

I just replaced the kicker gear and what postion on the clock do i set the kicker at ????1973 bonnieville t140


http://www.triumphrat.net/attachments/classic-vintage-and-veteran/24674d1272815144-kickstart-stuck-78-bonneville-dsc00425.jpg

Notice the top most tooth is kind of aligned with the cover mounting bolt hole above it.

You want to be sure that the kickstarter gear does not engage the transmission shaft ratcheting gear when the kick starter lever is all the way up.

Aug 15, 2011 | Triumph Bonneville Motorcycles

1 Answer

I have a 2005 RMZ 450. The rod on the crank shaft blew apart and i had to replace both cases, crank, piston and rings, get the cylinder fixed and plated. I had a local Suzuki shop replace everything. ...


Sounds like your ratchet gear is mis aligned, when you put the ratchet gear together it has alignment marks that have to line up when you insert it back in the case...The kick shaft being bent slightly should not prevent the engine from turning over. I hope this helps.

Jul 21, 2011 | Suzuki RM-Z 450 Motorcycles

1 Answer

Kick starter failure honda xl 250 kickstarter does not turn the engine around as if something has twisted off inside the engine


You will need to remove the right sidecase cover to get to the starter assembly. Once inside, you should be able to see any broken parts. If no gear, shaft, cam or ratchet problems are present, a circlip could be broken or the springs may be weak and need replacing. Chances are the clutch will need to be removed to make repairs to the starter. Please rate my answer.
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Aug 27, 2010 | 1989 Honda GL 1500 Gold Wing

1 Answer

Have 350 dirt bike kick start was ok left bike shed for a while used kickstart ok but next time it appears jammed wont move tried rocking in gear to free up but no go. Do you have an idea as to what might...


Assuming the engine will turn over, the ratcheting assembly on the kick starter may be worn. Remove the kick start lever and then the side cover, (place a pan under the bike to catch any oil). The kick starter is basically just a gear and a spring; the gear will in some manner engage the flywheel, (sometimes indirectly). Make sure there is nothing obvious wrong such as broken teeth or debris lodged in the mechanism.

The other possibility if the engine does not move when rolled is the timing chain may have jumped teeth on the cam sprocket. To get to this remove the gas tank, remove all but the rear engine mounting bolts, remove the valve cover. To check remove the fly wheel cover set the piston to Top Dead center, (TDC) on the compression stroke and make sure the mark on the cam sprocket is at the top of the sprocket and not off set.

Good luck.

Apr 01, 2010 | 1972 Honda CB 350 F0

2 Answers

My drz 110 makes a ratcheting sound and wont turn over


the main shaft has broken and possibly the first gear and right engine case. Common problem.

Jan 06, 2010 | 2005 kawasaki KLX 110

1 Answer

Kickstarter doesn't grab, it just ratchets through the gears. Any suggestions?


823dd83.jpgyou should have a no good
tension from the spring 92081 and check out for worn gear 13078 and 59051....sometime we just we strech the spring a litle and it help alot
and it lot less expensive but you have to get it to the right tension
you will also need a new clutch cover gasket.

Sep 19, 2009 | 2006 kawasaki KLX 110

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