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Harley-Davidson Motorcycle Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 31-10-2010

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2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 Figure 2. Exposed Shoulders Mark shifter fork rod flush with case Remove Spacers Vehicle Transmission Counter Shaft Main Shaft Front of Motorcycle Figure 1
Reverse Gear Installation Instructions For EVO / 5 Speed and Twin Cam Harley-Davidson® Motorcycle Page 3 of 6 Revision 7 © 2007 Champion Motorcycle Accessories International, Inc. dba Champion Sidecars 11841 Monarch Street Garden Grove, CA 92841 (800) 875-0949 (714) 847-0949 www.championsidecars.com www.championtrikes.com Figure 6 CAUTION: Do not pull the shifter fork rod out of the transmission more than 1/4″. If you pull the shifter fork rod out too far, it will be difficult to realign it with the internal shifter fork. 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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HARLEY-DAVIDSON 5 Speed Transmissions 1984 – 1999 EVO / 5 Speed & 1999 – 2006 Twin Cam Installation Instructions

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Filed Under (Harley Davidson) by admin on 26-11-2010

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Remove Original Parts From Vehicle. 2.1 Obtain a small tube of Loctite® #262 (red) for use later. 2.2 Drain the transmission oil. 2.3 Remove the clutch adjustment cover (left side). 2.4 Remove rear exhaust header pipe (cross over exhaust pipe). 2.5 Remove the muffler support bracket. 2.6 Remove the clutch release cover (right side). 2.7 Remove clutch push rod and oil slinger. To be disassembled and modified later. 2.8 Remove the two nuts from the main (rear) and counter (front) transmission shafts. 2.9 Remove the transmission bearing housing (puller available from Champion Sidecars). To be replaced with new reverse gear transmission bearing housing (Trap Door). 2.10 Cover the exposed gears in the transmission with a cloth in preparation to cut the shifter fork shaft. 3 Install New Main and Countershaft Gears NOTE: Gears and Tapered Split Rings are factory matched sets. Do not mix!. 3.1 Locate the shifter fork rod, mark fork rod flush at transmission case and pull out 1/4″. Figure 1 3.2 Cut the shaft at the mark and push it back in. The shaft end MUST NOT stick out of the transmission case. If the shaft is in deeper, fill the hole with silicone to prevent the shaft from moving in and out. NOTE: Shifter fork is made of non-tempered metal and may be cut with a hacksaw or Dremel® cutting tool. 3.3 Important: Remove stock spacers from main and counter shafts. Spray with silicon remover (Brake-Clean) then, using supplied cleaning pad, clean shafts, new counter and main shaft gears and tapered lock rings (inside and outside) Figure 1 3.4 With motorcycle in neutral, pull both the shafts out and simultaneously push the OEM outermost gears in until seated completely to expose the shoulders of both shafts. The countershaft shoulder should be flush with the gear face. For the main shaft the gear would “hang over” the shoulder a small bit. Figure 2 3.5 Apply supplied Champion Super-Lock retaining compound to the inside and outside surfaces of the large gear tapered split ring, to the inside of the new countershaft gear (large gear) and to the transmission countershaft (the forward most shaft). 3.6 Install new countershaft gear to the transmission countershaft. Insert tapered split ring (tapered end first) into the countershaft gear. Install ring seat tool and spring to counter shaft and new countershaft gear. Torque ring seat tool to 40 ft-lb’s. Figures 3 and 4

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HARLEY DAVIDSON SHIFTER SHAFT COVER WITH INSERT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION 1 2 4 3 5 6 7 is01872 1. Shifter shaft 2. Inner cover 3. Toe shifter lever 4. Outer cover 5. Set screw (for outer cover) 6. Set screw (for inner cover) 7. Casting Figure 1. Shifter Shaft Covers 1. See Figure 1. Remove the stock heel shift lever and toe shift lever (3) from the gear shifter shaft (1). 2. Install the set screw (6) into the inner gear shifter shaft cover (2). 3. Install inner gear shifter shaft cover with installed set screw over the casting (7) in-board of the shifter shaft (1). 4. Tighten the set screw until light contact is made with the casting. Do not overtighten. 5. Re-install toe shift lever on the gear shifter shaft. Tighten the shifter retaining screw to 18-22 lb-ft (24-30 Nm) . 6. Install the set screw (5) into the outer gear shifter cover (4). 7. Install outer gear shifter shaft cover with installed set screw over the end of the gear shifter shaft (1). 8. Loosen the set screw slightly to allow the gear shifter shaft cover to rotate. Rotate the cover until the set screw faces down, then tighten the set screw. SERVICE PARTS

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION

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Filed Under (Harley Davidson) by admin on 25-12-2010

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1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit. NOTE For models with mid controls, the right-side rider footrest (foot peg) support bracket must be loosened to allow installation of the lower side interface cover. After the cover has been installed, tighten the footrest bracket attaching screws to 25- 35 ft-lbs (34-47 Nm) . 8. Position the cover around the chrome filler neck cover installed in Step 6. Loosely fasten the cover to the threaded hole in the filler neck cover with the screw and washer. 9. Obtain the chrome upper side interface cover (2), three #10-24 socket head screws (8) and three chrome flat washers (9) from the kit

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HARLEY DAVIDSON ENGINE/ TRANSMISSION INTERFACE AND TOP COVER INSTALLATION INSRUCTIONS

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Filed Under (Harley Davidson) by admin on 31-01-2011

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INSTALLATION Perform this installation when the engine is cool. Working on or near the exhaust system when the engine is hot could result in severe burns. (00311a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the maxi-fuse. 3 1 2 is02998 1. Transmission top cover screw (4) 2. Oil spout assembly screw 3. Upper bearing housing screw (2) Figure 1. Interface Cover Installation 2. See Figure 1. Remove and retain the four socket head cap screws (1) that fasten the front and right side of the transmission cover. See Figure 3. Obtain the chrome top interface cover (3) from the kit. NOTE The top interface cover can be carefully brought into position on top of the transmission housing from either the right or left side without removing or loosening any vehicle components. 3. Position the top interface cover over the transmission top cover. Loosely fasten the chrome cover to the top of the transmission housing with the screws removed in Step 2. 4. Obtain the chrome filler neck cover (4), 1/4-20 socket head screw (5), flat washer (6) and spacer (7) from the kit. Remove the oil level dipstick from the oil spout on the side of the transmission housing, wipe off and set it aside for later installation. NOTE Insert a clean shop rag into the oil spout opening while the dipstick is not installed. With the dipstick removed, small parts or other foreign material could fall into the transmission, leading to equipment damage or malfunction. 5. See Figure 1. Remove and discard the socket head cap screw (2) that fastens the oil spout assembly to the transmission housing. DO NOT remove the oil spout from the vehicle. 6. Place the flat washer over the threads of the new screw, and insert the screw into the unthreaded hole in the chrome filler neck cover. Place the spacer onto the screw threads. Apply a few drops of Loctite® 243 (Blue) to the screw threads, and position the chrome cover onto the oil spout on the transmission housing. Lubricate the filler neck gasket with soapy water to aid in installation. Tighten the screw to 84-132 in-lbs (9.5-15 Nm) . 7. See Figure 3. Obtain the chrome lower side interface cover (1), one #10-24 socket head screw (8) and one chrome flat washer (9) from the kit

Harley-Davidson Six Speed Transmissions FLH 2009 Up Champion Reverse Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 17-02-2011

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Preparation Remove Original Parts From Vehicle. 2.1 Purchase a small tube of Loctite #262 (red) for use later. 2.2 To torque the large gear: 2.2.1 Purchase Snap-On (or equivalent) filter tool. Part #: FWA62121. OR 2.2.2 Purchase Champion special tool – Part # RG-100-100 2.3 Drain the transmission oil. 2.4 Remove front and rear exhaust header pipe. 2.5 Remove the clutch release cover (right side). 2.6 Remove throw out bearing assembly. (to be reinstalled later without modification) 2.7 Remove the two nuts from the main and counter transmission shafts. WARNING : Do not attempt to push shafts into gearbox or remove the trap door – This can cause spacers inside the gearbox to be miss-aligned and lock up the gearbox when gears are installed and tightened. 2.8 Remove clutch push rod (to be replaced w/ Champion supplied rod) Note: For hydraulic clutch bikes, obtain Champion Part # RG-100-082, a longer push rod) Snap-On Part No: FWA62121 Snap-On Part No: FWA62121 Champion Part No: RG-100-100 Reverse Gear Installation Instructions Harley-Davidson Six Speed Transmission HD FLH 2009 Up Page 3 of 5 Revision 2 Boring Tool 3 Installation 3.1 Thoroughly clean threads of main and counter shafts using a silicon remover. 3.2 Apply the green thread locking compound (supplied) to main shaft threads and screw the small gear onto the main shaft. Figure 1 3.3 Install the supplied (ear)plug into the main shaft hole. To be removed later. 3.4 Install the supplied special tool to the small gear. Ensure the holes of the special tool align with the holes in the small gear. Figure 2 3.5 Install torque wrench to special tool and torque the small gear to 80 lb. ft. 3.6 Remove torque wrench from special tool. Do not remove special tool from small gear. 3.7 Using the supplied boring tool and the special tool as a guide, drill the main shaft through two holes of the special tool as shown. Stop when cutter contacts bearing race. Figure 3 3.8 Remove special tool, leaving main shaft plug in place, and thoroughly clean out the holes. Use care to ensure debris does not enter transmission. 3.9 Remove plug from main shaft hole. Figure 1 Figure 2 Figure 3 Note: To prevent gears from rotating during torque procedures, engage transmission into 1st gear and apply brakes Note: Frequently stop cutting and remove bit from hole to clean bit and vacuum debris from hole

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Harley Davidson Twist Gear and Wide Gear Installation Instructions

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Filed Under (Harley Davidson) by admin on 11-04-2012

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Assemble triple lip output seal 705002 and output spacer 280001 together. The seal is shipped with high performance grease packed into the seal lips to ensure lubrication and exclude dust & water. (Caution: Only high temperature grease should be used, grease is better than oil, never install the seal dry.) Slide the quad ring and seal/spacer assembly onto the transmission output shaft, then slide tool JE300001 ( TwistGear TM ) or JE300002 ( WideGear ) onto the shaft and finally tighten the nut until the tool drives the seal flush with the case. Do not attempt to install the main drive seal without the JE tool or the seal will be damaged, and the seal performance will be compromised (the JE seal is wider around the shaft for the third sealing lip, which will be damaged if a tool is pressed against it.) It is best that a new JE spacer be used each time a new seal is installed for quick break-in of the main lip seal surface. Counter Shaft Assembly Note the order and orientation of the gears on the counter shaft when it is removed from the trapdoor. Disassemble the counter shaft and transfer the parts to the TwistGear TM counter shaft. Note that the TwistGear TM counter shaft assembles in different order than the OEM counter shaft. Two washers are required in the position as shown in figure 1 (see arrow) before the retainer ring is installed. The second washer is included in the kit.

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HARLEY DAVIDSON SOFTAIL TRANSMISSION TOP-COVER KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 03-02-2011

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INSTALLATION – TOP COVER 1. See Figure 3. Remove and retain the stock screw (J) from the top of the transmission upper cover (I). 2. Ease the left side of the cover through the right side of the engine. You may need to angle the transmission cover slightly as you work it into position. 3. Fasten the weld-nut end of the top-cover bracket (2) to the top cover (4) using the screw (3) from the kit. Torque the screw to 6.6 – 9 ft-lbs (8.9 – 12.2 Nm). 4. Fasten the top of the top-cover bracket (2) to the left side of the transmission upper cover using the screw (J) removed in step 1. Torque the screw to 8 – 10 ft-lbs (10.8 – 13.5 Nm). 5. Install the Softail transmission-interface cover (D). Go to the next section in this instruction sheet. NOTE Save the washer (1) from this kit for transmission-interface cover installation. INSTALLATION – INTERFACE COVER 1. See Figure 1. Remove the screw (1) from interface cover at location 1. Keep the screw for installation. 2. Loosen the screw (2) at location 2 approximately three turns. 3. See Figure 2. Position the slotted hole (1) on the interface- cover mounting bracket (2) behind the washer at location 2. 4. Install the screw (4) from Step 1 through the mounting hole on the bracket and into location 1. Tighten the screw to 7 – 9 ft-lbs (9.5 – 12 Nm). 5. Tighten the screw (3) in location 2 to 13-16 ft-lbs (17.6 – 21.7 Nm). 6. See Figure 3. Place the interface cover (D) in position on the motorcycle. Spread the oil-line grommet (E) to wrap around the oil lines, then re-position the grommet in the interface cover. The edge of the interface cover must overlap the top of the top cover

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Harley Davidson 6- SPEED CONVERSION KIT FOR BIG TWIN 5- SPEED TRANSMISSIONS INSTALLATION

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Filed Under (Harley Davidson) by admin on 05-03-2012

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5/16 Bolt hole boss clearance This can easily be checked with the trap door gasket. Put the gasket on the dowel pins. AII material of the boss around the hole that “sticks outside” the gasket (60 degrees forward to 60 degree backwards) must be removed (see figure A). Primary fork clearance Place the gasket on the housing and remove material as indicated for clearing the shifter fork (see figure B). WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® INSTALLATION INSTRUCTIONS FOR 6 SPEED CONVERSION KIT AND 6 SPEED BUILDER KIT speed transmission. Also make sure you have a 1990 or later Factory Service Manual available. Tools The conversion kit should only be used in new or low milage transmissions. If gears or bearings of a used Gear set Removal Refer to the Factory Service Manual Section for Mainshaft and Countershaft removal. When you get to the point of actually sliding the gear set out make sure you properly mark the 5th gear set as described in the Factory Service Manual (for used transmissions only). Further follow the factory removal procedure. Clearance Checks The 6 Speed conversion and builder kit will fit in most OEM or aftermarket transmission housings without may be needed. The following clearances must be checked before assembling the 6 speed transmission. 28-05-2008 We recommend the kits are installed by a qualified mechanic with knowledge of the Harley-Davidson 5 needed are the same as used for a 5 Speed transmission. 5 speed transmission are worn, new ones must be installed, or better, the builder kit should be used. any modification of the housing. However due to casting differences, in some instances some modification
WWW . ZODIAC . NL PERFORMANCE PRODUCTS FOR HARLEY-DAVIDSON ® Pillow block clearance (right side) Make sure there is clearance between the pillow block and the housing. Any clearance is O.K. (see figure C). Fork shaft support clearance Again use the gasket as the template and remove the material as indicated (see figure D). Shift drum end play The end play of the shift drum must be checked prior to final installation. Install the shift drum. Measure the end play with feeler gauges at the right pillow block (see figure E). End play should be between .004″ and .010″, some 1/2″ X 7/8″ 0.008″ thick shims are included to adjust the end play

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HARLEY DAVIDSON 45-AMP. UPGRADE ALTERNATOR ROTOR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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This 45-amp Rotor Kit is designed for installation on 1999 and later FLHT, FLHTC, FLHR, FLHRI, FLHRCI and FLTR Model Motorcycles. Existing Rotor Removal 1. Remove seat and disconnect battery terminals, negative cable first. 2. Follow instructions in applicable Service Manual and remove the primary chaincase cover. Remove the clutch, primary chain, compensating sprocket and shaft extension as a single assembly. 3. Remove the alternator rotor spacer, if present. Installation The laminated high-output rotor in this kit contains magnets that are considerably more powerful than those used in most previous rotors. The ROTOR REMOVER/INSTALLER and SHAFT PROTECTOR SLEEVE (HD-41771) must be used to prevent parts damage during rotor removal and installation. 1. See Figure 1. Verify threads are clean and thread the Shaft Protector and Rotor Remover/Installer, if removed. NOTE The Shaft Protector Sleeve not only protects the threads from the splines of the rotor, but acts as a guide to ensure that the rotor is properly centered. 2. Turn thumbscrews of Rotor Remover/Installer into threaded holes in rotor face. CAUTION 1 WARNING 1 WARNING 1 WARNING Kit Number 29999-97B Figure 1. Install Shaft Protector and Rotor Installer Engine Sprocket Shaft 1. Make Sure Threads are Clean 2. Install shaft protector sleeve. Shaft protector sleeve 3. Install Rotor Remover/Installer i04153 Handle Thumbscrew Forcing screw . Center ball on forcing screw in recess at end of engine sprocket shaft. Rotate the handle of the tool in a counterclockwise direction to ease rotor into position over stator. 4. Loosen thumbscrews and remove Rotor Remover/Installer. Remove Shaft Protector Sleeve. 5. Install the shaft extension on engine sprocket shaft. No alternator rotor spacer is necessary). 6. Follow instructions in applicable Service Manual and install the clutch assembly, primary chain and shaft extension as a single assembly. 7. Apply two drops of Red LOCTITE®262 to threads of clutch nut and engine sprocket nut. Tighten nuts as fol- lows: Clutch nut- (left hand threads), 70-80 ft-lbs (94.9-105.5 Nm) Engine sprocket nut- 150-165 ft-lbs (203-223 Nm). 8. Follow instructions in Service Manual and install the Primary Chaincase Cover using new gasket from kit, if necessary.

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