Harley Davidson Softail 2000-2005. Service manual - page 20

1. Mainshaft bearing race puller and installation tool
(JIMS part No. 34902-84).
2. Five-speed door puller (JIMS part No. 2283).
3. Transmission door bearing remover and installer
(JIMS part No. 1078).
4. Transmission shaft installers (JIMS part No. 2189).

Removal

Remove the transmission and side door assembly as fol-

lows:
1. Remove the exhaust system as described in Chapter
Seven.
2. Drain the transmission oil as described in Chapter
Three.
3. Remove the primary chaincase cover as described in
Chapter Five.
4. Remove the clutch release cover and clutch assembly
as described in Chapter Five.
5. Remove the primary chaincase housing as described in
Chapter Five.
6. Remove the shift forks as described in this chapter.
7. Remove the bearing inner race (Figure 24) from the
mainshaft as follows:

a. Attach the mainshaft bearing race puller and instal-

lation tool (Figure 25) to the inner bearing race fol-
lowing the manufacturer’s instructions.

b. Tighten the puller bolt (A, Figure 26) and withdraw

the inner race (B) from the mainshaft.

8. Remove the oil slinger assembly (B, Figure 17).
9. Turn the transmission by hand and shift the transmis-
sion into two different gears to keep the gears from turning.

NOTE

The mainshaft and countershaft have
left-hand threads. Turn the nuts

clockwise

loosen them.

10. If the transmission gear assemblies are going to be re-
moved from the side door, loosen, but do not remove, the
countershaft and mainshaft locknuts.
11. If the main drive gear is going to be removed, remove
the drive sprocket as described under

Drive Sprocket

Chapter Nine.
12. Remove the bolts securing the transmission side door
to the transmission case.

CAUTION

When removing the transmission side door
in Step 13, do not tap the transmission shafts
from the opposite side. This will damage the
side door bearings.

13. Tap the transmission side door to loosen its seal with
the transmission case.

14. Install the five-speed door puller (Figure 27) onto the
door following the manufacturer’s instructions. Tighten
the outside screws one-half turn at a time alternating from
side-to-side until the door releases from the transmission
case. Remove the special tool.

15. Slowly withdraw the transmission side door and the
transmission gear assemblies from the transmission case.

16. Remove the transmission side door gasket. Do not
lose the locating pins.

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CHAPTER SIX

17. If necessary, service the side door and transmission
assembly as described in this chapter.

Installation

1. If the main drive gear was removed, install it as de-
scribed in this chapter.
2. Remove all gasket residue from the side door and
transmission case mating surfaces.
3. Install a

new

gasket onto the transmission case. If the

locating pins were removed, install them.
4. Install the side door and transmission assembly into
the transmission case. Make sure the side door fits flush
against the transmission case.
5. Install the transmission side door 5/16 in. and 1/4 in.
bolts finger-tight. Tighten the 5/16 in. bolts to 13-16 ft.-lb.
(18-22 N•m). Then tighten the 1/4 in. bolts to 84-108
in.-lb. (9-12 N•m).
6. Turn the transmission by hand and shift the transmis-
sion into two different gears to keep the gears from turning.
7. Install the bearing inner race (Figure 24) onto the
mainshaft as follows:

a. The

bearing

inner

race

0.950-1.000

in.

(24.13-25.40 mm) long. When installing a

new

race,

measure it to confirm its length. Race length deter-
mines its installation position.

b. Use the same special tool set-up used for bearing in-

ner race removal.

c. Apply clean oil to the transmission shaft bearing sur-

face, shaft threads and inner surface of the inner race.

d. Position the bearing inner race with the chamfered

end going on first and slide it onto the mainshaft
(Figure 28).

e. Install the extension shaft onto the mainshaft.

f. Place the pusher tube, the two flat washers and nut

over the extension shaft.

NOTE

The mainshaft and countershaft nut have
left-hand threads. Turn each nut

counter-

clockwise

to tighten it in substep g.

CAUTION

Install the inner bearing race to the dimen-
sion in substep g. This aligns the race with
the bearing outer race installed in the pri-
mary chaincase. Installing the wrong race
or installing it incorrectly will damage the
bearing and race assembly.

g. Hold the extension shaft and tighten the nut to press

the bearing inner race onto the mainshaft. Install the
race so its inside edge is 0.100-0.150 in.
(2.540-3.810 mm.) away from the main drive gear.

h. Remove the special tools.

8. Install the oil slinger assembly (B, Figure 17).

9. Install the shift forks as described in this chapter.

10. Install the primary chaincase housing as described in
Chapter Five.

11. Install the clutch assembly and clutch release cover as
described in Chapter Five.

12. Install the primary chaincase cover as described in
Chapter Five.

13. Install the drain plug and refill the transmission oil as
described in Chapter Three.

14. Install the exhaust system as described in Chapter
Seven.

15. Test-ride the motorcycle slowly and check for proper
transmission operation.

TRANSMISSION SHAFTS

This section describes service to the side door and both

transmission shaft assemblies.

TRANSMISSION

239

Mainshaft

Bearing inner race

Extension shaft

Disassembly

The transmission shaft assemblies (Figure 29) must be

partially disassembled prior to removing both shafts from
the side door. Do not try to remove the shafts with all of
the gears in place.

The snap rings are difficult to loosen and remove even

with high-quality snap ring pliers. Heavy-duty retaining
ring pliers (H-D part No. J-5586), or an equivalent, is rec-
ommended for this procedure.

Store all of the transmission gears, snap rings, washers

and split bearings in the order of removal.

1. Remove the transmission side door and transmission
shaft assemblies as described in this chapter.

2. Protect the splines and threads on the mainshaft with
tape or a plastic sleeve (Figure 30).

3. Remove the mainshaft second gear (Figure 31).

4. Remove the snap ring (Figure 32) from the countershaft.

5. Remove the countershaft fifth gear (Figure 33).

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CHAPTER SIX

1. Mainshaft first gear
2. Mainshaft
3. Snap ring
4. Thrust washer
5. Mainshaft third gear
6. Mainshaft second gear
7. Split bearings
8. Oil slinger assembly
9. Clutch pushrod

10. Locknut
11. Washer

TRANSMISSION

12. Side door
13. Gasket
14. Spacer
15. Mainshaft fourth gear
16. Spacer
17. Countershaft fourth gear
18. Countershaft first gear
19. Countershaft
20. Countershaft third gear
21. Countershaft second gear
22. Countershaft fifth gear

6. Remove the countershaft second gear (Figure 34).

CAUTION

Do not expand the split bearings any more
than necessary to slide them off the shaft.
The bearing carriers are plastic and will
fracture if expanded too far.

7. Remove the split bearing (Figure 35) from the
countershaft.

8. Slide off the washer and remove the snap ring (Figure
36) from the countershaft.

TRANSMISSION

241

9. Remove the countershaft third gear (Figure 37).

NOTE

The snap ring in Step 10 must be released
and moved in order to gain access to the
snap ring on the other side of the third gear.

10. Using snap ring pliers, release the snap ring (Figure
38) behind the mainshaft third gear. Slide the snap ring
away from the third gear.

11. Slide the third gear toward the side door and remove
the snap ring (Figure 39) and washer.

12. Remove the mainshaft third gear (Figure 40).

13. Remove the washer and snap ring (Figure 41).

14. Remove the split bearing (Figure 42) from the
countershaft.

15. Place a brass or aluminum washer (Figure 43) be-
tween the countershaft fourth gear and the mainshaft
fourth gear. This locks both transmission shafts from rota-
tion.

16. If not loosened during

Removal

, loosen and remove

the locknuts and washers (Figure 44) securing the shaft
assemblies to the side door. Remove the brass or alumi-
num washer from between the shafts. New locknuts must
be installed during assembly.

242

CHAPTER SIX

17. Press the countershaft out of its side door bearing as
follows:

a. Support the countershaft first gear in a press with a

tube (A, Figure 45) so the countershaft can be
pressed out without interference. Center the
countershaft under the press ram.

b. Place a mandrel (B, Figure 45) on top of the

countershaft and press the countershaft out of the
side door.

18. Remove the spacer (A, Figure 46), fourth gear (B),
first gear (C) and washer (D) from the countershaft.

19. Remove the split bearing (A, Figure 47) from the
countershaft.

20. If necessary, remove the snap ring (B, Figure 47)
from the countershaft.

21. Remove the first gear (Figure 48) from the
mainshaft.

22. Remove the ring snap and washer (A, Figure 49)
from the mainshaft.

23. Press the mainshaft out of its side door bearing as fol-
lows:

a. Support the mainshaft fourth gear on a tube (A, Fig-

ure 50) in a press so the mainshaft can be pressed

TRANSMISSION

243

out without interference. Center the mainshaft un-
der the press ram.

b. Place a mandrel (B, Figure 50) on top of the

mainshaft and press the mainshaft out of the side
door.

24. Remove the fourth gear and spacer (B, Figure 49)
from the mainshaft.
25. Inspect all parts as described in this section.

Inspection

Maintain the alignment of the transmission components

when cleaning and inspecting the individual parts in the
following section. To prevent intermixing parts, work on
only one shaft at a time.

Refer to Table 2 and inspect the service clearance and end

play of the indicated gears and shafts. Replace parts that are
excessively worn or damaged as described in this section.

CAUTION

Do not clean the split bearings in solvent. Re-
moving all traces of solvent from the bearing
plastic retainers is difficult. Flush the bear-
ings clean with new transmission oil.

1. Clean and dry the shaft assembly.
2. Inspect the mainshaft and countershaft for:

a. Worn or damages splines (A, Figure 51).
b. Excessively worn or damaged bearing surfaces.
c. Cracked or rounded-off snap ring grooves (B, Figure

51).

d. Worn or damaged threads (C, Figure 51).

3. Check each gear for excessive wear, burrs, pitting, or
chipped or missing teeth. Check the inner splines (Figure
52) on sliding gears and the bore on stationary gears for
excessive wear or damage.
4. Check the gear bushings (Figure 53) for wear, cracks
or other damage.
5. To check stationary gears for wear, install them in their
original operating positions. If necessary, use the old snap
rings to secure them in place. Then spin the gear by hand.
The gear should turn smoothly. A rough turning gear indi-
cates heat damage. Check for a dark blue color or galling
on the operating surfaces. Rocking indicates excessive
wear to the gear and/or shaft.
6. To check the sliding gears, install them in their original
operating positions. The gear should slide back and forth
without any binding or excessive play.
7. Check the shift fork groove (Figure 54) for wear or
damage.
8. Check the dogs on the gears for excessive wear, round-
ing, cracks or other damage. Refer to Figure 55. When

244

CHAPTER SIX

wear is noticeable, make sure it is consistent on each gear
dog. If one dog is worn more than the others, the others
will be overstressed during operation and will eventually
crack and fail. Check engaging gears as described in Step
10.

9. Check each gear dog slot for cracks, rounding and other
damage. Check engaging gears as described in Step 10.

10. Check engaging gears by installing the two gears on
their respective shafts and in their original operating posi-
tion. Mesh the gears together. Twist one gear against the
other and check the dog engagement. Then reverse the
thrust load to check the other operating position. Make
sure the engagement in both directions is positive and
there is no slippage. Make sure there is equal engagement
across all of the engagement dogs.

NOTE

If there is excessive or uneven wear to the
gear engagement dogs, check the shift forks
carefully for bends and other damage. Refer
to

Shifter Assembly

in this chapter.

NOTE

Replace defective gears and their mating
gears, though the mating gears may not
show as much wear or damage.

11. Check the spacers (Figure 56) for wear or damage.

12. Check the split bearings (Figure 57) for excessive
wear or damage.

13. Replace all of the snap rings during reassembly.
Check the washers for burn marks, scoring or cracks. Re-
place as necessary.

Side door bearings inspection and replacement

The side door bearings (Figure 58) are pressed into

place and secured with a snap ring. They can be removed
and installed with a transmission door bearing remover

TRANSMISSION

245

246

CHAPTER SIX

TRANSMISSION CASE, BEARINGS AND COVERS

1. Speed sensor electrical connector
2. Secondary lock
3. Bolt
4. Neutral indicator switch
5. O-ring
6. Bolt
7. Vent hose
8. 90

fitting

9. Cover

10. Screw
11. Speed sensor
12. O-ring
13. Gasket
14. Dowel pin
15. Transmission case
16. Mainshaft bearing (left side)
17. Snap ring
18. Quad seal
19. Oil seal
20. Sprocket spacer
21. Bearing
22. Dowel pin
23. Bolt
24. Washer
25. Screw
26. Washer
27. Screw
28. Mounting bracket
29. O-ring
30. Drain plug
31. Transmission side door
32. Gasket
33. Locating pin
34. Locknut
35. Washer
36. Snap ring
37. Bearing
38. Bolt
39. Bolt
40. Clutch release cover
41. Screw
42. O-ring
43. O-ring
44. Filler plug/dipstick
45. Outer ramp
46. Coupling
47. Ball (3)
48. Inner ramp
49. Snap ring
50. Gasket

and installer (JIMS part No. 1078) (Figure 59). If this spe-
cial tool set is not available, a press is required.
1. Clean the side door and bearings in solvent, and dry
them with compressed air.
2. Turn each bearing inner race (Figure 60) by hand. The
bearings must turn smoothly. If they need to be replaced,
continue to Step 3.
3. Remove both snap rings (Figure 61) from the outer
surface of the side door.
4A. To remove the bearings with the special tool set, fol-
low the manufacturer’s instructions.
4B. Remove the bearings with a press as follows:

a. Support the side door on the press bed with the outer

surface facing up.

b. Use a driver or socket to press the bearing out of the

backside of the side door.

c. Repeat substep b for the opposite bearing.

5. Clean the side door in solvent and dry it thoroughly.
6. Inspect the bearing bores in the side cover for cracks or
other damage. Replace the side door if it is damaged.

NOTE

Both side door bearings have the same part
number.

7A. To install the bearing with the special tool set, follow
the manufacturer’s instructions.
7B. Install the bearing with a press as follows:

a. Support the side door in a press with the backside

facing up.

b. Install bearings with their manufacturer’s marks

facing out.

c. Use a driver that matches the bearing outer race.

Press the bearing into the side door until it bottoms.

d. Repeat substeps b and c for the opposite bearing.

8. Position the beveled snap ring with the sharp side (Fig-
ure 62) facing toward the bearing outer race and install
the snap ring. Make sure the snap ring is correctly seated
in the side door groove.

Assembly

Refer to Figure 63.

CAUTION

Install

new

snap rings at every location to

ensure proper gear alignment and engage-
ment. Never reinstall a snap ring that has
been removed since it is distorted and weak-
ened, and may fail. Make sure each

new

snap ring is correctly seated in its respective
shaft groove.

TRANSMISSION

247

Rounded edges

Sharp edges

Direction of thrust

1. Apply a light coat of clean transmission oil to all mat-
ing gear surfaces and to all split bearing halves before as-
sembly.

2. If removed, install the side door bearings as described
in this chapter.

3. Install the following onto the mainshaft:

a. If the snap ring was removed, install a

new

snap ring

(Figure 64).

b. Position the first gear with the shift dog side going

on last and install the first gear (Figure 65).

c. Install the snap ring (A, Figure 66) and washer (B).

d. Install the split bearing (Figure 67).

248

CHAPTER SIX

TRANSMISSION

1. Mainshaft first gear
2. Mainshaft
3. Snap ring
4. Thrust washer
5. Mainshaft third gear
6. Mainshaft second gear
7. Bearings
8. Oil slinger assembly
9. Clutch pushrod

10. Locknut
11. Washer

e. Position the fourth gear with the shift dog side go-

ing on first and install the fourth gear (Figure 68).

f. Position the spacer with the beveled side facing out

(Figure 69) and install the spacer.

4. Install the following onto the countershaft:

a. If the snap ring was removed, install a

new

snap ring

(A, Figure 70).

b. Install the washer (B, Figure 70) and push it against

the snap ring.

c. Install the split bearing (Figure 71).

TRANSMISSION

249

d. Position the first gear with the shoulder side (Fig-

ure 72) going on last and install the first gear onto
the split bearing (Figure 73).

e. Position the fourth gear with the wide shoulder

(Figure 74) going on first and install the fourth
gear.

f. Position the spacer with the beveled side facing out

(Figure 75) and install the spacer.

5. Apply transmission oil to the inner race of both bear-
ings and to the shoulder of both shaft assemblies. Also ap-

ply transmission oil to the inner threads and ends of the
special tools used in Step 8.

6. Position the countershaft (A, Figure 76) on the left
side of the side door. Position the mainshaft (B, Figure
76) on the right side of the side door.

7. Mesh the two shaft assemblies together and start them
into the side door bearings (Figure 77).

8. Attach the shaft installers (JIMS part No. 2189) onto
the ends of both shafts.

250

CHAPTER SIX

9. Tighten the shaft installers (Figure 78), alternating be-
tween both shafts, until both shaft shoulders bottom on the
inner race of the side door bearings (Figure 79).

10. Unscrew and remove the special tools.

CAUTION

Always install

new

locknuts. If an old

locknut is reinstalled, it may work loose and
cause transmission damage.

11. Install the spacers (A, Figure 80) and

new

locknuts

(B).

12. Start the

new

locknuts by hand until the locking por-

tion of the nut touches the end of the transmission shaft.

13. Place a brass or aluminum washer between the
countershaft fourth gear and the mainshaft fourth gear.
This will lock both transmission shafts.

14. Tighten the locknuts (Figure 81) to 45-55 ft.-lb.
(61-75 N•m).

15. Install the following onto the mainshaft:

a. Install the split bearing (Figure 82).

b. Move the snap ring (A, Figure 83) installed in Step

3 out of the groove and toward the first gear.

TRANSMISSION

251

c. Install the washer (B, Figure 83) and slide it against

the snap ring (A, Figure 84).

d. Position third gear with the shift dogs side (B, Fig-

ure 84) going on last. Install the third gear onto the
split bearing (Figure 85).

e. Install the washer (A, Figure 86) and snap ring (B).

Make sure the snap ring is correctly seated in the
mainshaft groove.

f. Move third gear away from the first gear, and up

against the washer and snap ring installed in substep e.

g. Reposition the washer and snap ring behind third

gear. Make sure the snap ring is correctly seated in
the mainshaft groove.

16. Install the following onto the countershaft:

a. Position the third gear with the shift fork groove

(Figure 87) side going on last and install the third
gear.

b. Install the snap ring (A, Figure 88) and washer (B).

c. Install the split bearing (Figure 89).

252

CHAPTER SIX

d. Position the second gear with the shift dog side

(Figure 90) going on first. Install the second gear
onto the split bearing (Figure 91).

17. On the mainshaft, position the second gear with the
shift fork groove (Figure 92) side going on first and in-
stall the second gear (Figure 93).

18. On the countershaft, install the fifth gear (Figure 94),
then install the snap ring (Figure 95). Make sure the snap
ring is correctly seated in the countershaft groove.

19. Refer to Figure 96 for correct placement of all gears.
Also make sure the gears mesh properly to the adjoining

TRANSMISSION

253

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