Question about Harley Davidson XLH 1000 Sportster Motorcycles
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.
Posted on Oct 01, 2010
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Posted on Jan 02, 2017
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1-2 Shift Solenoid Valve
3-4 Shift Valve Bore Plug
Burned, slipping, missing
4th Servo Cover
4th Servo Pin
4th Servo Piston
4th Servo Seals
Rolled, cut or damaged
Slipping or No Fourth Gear
Slipping or No Fourth Gear Checks
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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