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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 12

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220

CHAPTER FIVE

85

86

d. Install the outer snap ring (clutch side). Make

sure the snap ring is correctly seated in the

87

groove.

CAUTION

When pressing the bearing into the

housing, support the outer snap ring.

The force required to press the bear-

ing into the inner primary housing

may force the snap ring out of its

groove, damaging the housing.

e. Support the inner housing and outer snap

ring.

f. Press the bearing into the inner housing until

it seats against the snap ring.

88

g. Install the inner snap ring (Figure 86). Make

sure the snap ring is seated correctly in the

groove.

h. Install a new oil seal as described in Step 7.

7. Inspect the inner primary cover oil seal (Figure

85) for excessive wear, tearing or other damage. To

replace the oil seal, perform the following:

a. Remove the oil seal with a wide-blade screw-

driver.

b. Clean the oil seal bore.

c. Pack the oil seal lip with a waterproof bearing

grease.

89

d. Position the oil seal with its closed side facing

out. Press in the new oil seal until its outer

surface is flush with the edge of the bearing

bore (Figure 87).

8A. On 1999-2000 models, check the primary chain

adjuster rack screws (Figure 88) for looseness.

Tighten the screws, if necessary.

8B. On 2001 models, check the primary chain ad-

juster rack screws

(Figure

89) for looseness.

Tighten the screws, if necessary.

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CLUTCH AND PRIMARY DRIVE

221

90

94

5

Installation

91

NOTE

In Step 1, apply the RTV sealant to the

inner surface of the two bolt holes.

Figure 90 shows only the bolt hole lo-

cation and is pointing to the outer sur-

face.

1. Thoroughly clean the inner surface of the two

lower bolt holes (Figure 90) of the inner cover. Ap-

ply a light coat of RTV to these inner surfaces.

2. On all models except FXDWG, if the shift lever

sleeve was removed, perform the following:

a. Install a new O-ring (Figure 91) onto the

92

outer groove.

b. Apply a light coat of RTV to the sleeve (Fig-

ure 92).

c. Pull the sleeve into the inner cover until the

grooves are visible on the outer side of the in-

ner cover.

d. Install the clip into the second groove and

tighten the bolt.

3. Install the O-ring (Figure 78) onto the engine

crankcase shoulder.

4. To prevent the mainshaft splines (Figure 93)

from damaging the inner cover oil seal as it passes

93

over, wrap the mainshaft splines with tape.

5. If removed, install the drive belt prior to install-

ing the inner housing.

6. On all models except the FXDWG, insert the in-

ner shift shaft (Figure 94) through the collar and in-

stall the inner housing.

7. Align the inner housing with the engine and

transmission and install it.

8. Apply a bead of RTV sealant around the outer

surface of the two bottom bolt holes (Figure 90).

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222

CHAPTER FIVE

95

STARTER JACKSHAFT

1. Bolt

2. Lockplate

3. Thrust washer (with

seal insert)

4. Pinion gear

5. Spring

6. Snap ring

7. Coupling

8. Jackshaft

9. Snap ring

10. Coupling

Snap ring groove

Snap ring groove

9. Install the inner housing bolts (Figure 76) and

new lockwashers (Figure 75).

96

NOTE

Tighten the inner housing bolts in the

following order.

10. Tighten the inner housing-to-engine mounting

bolts to the specification in Table

2. Bend the

lockwasher tabs against the bolt heads.

11. Tighten the inner housing-to-transmission

mounting bolts to the specification in Table 2. Bend

the lockwasher tabs against the bolt heads.

12. Install the starter jackshaft as described in this

chapter.

97

13. Install the starter motor as described in Chapter

Eight.

14. Install the compensating sprocket, primary

chain and clutch assembly as described in this chap-

ter.

15. Install the primary chaincase outer cover as de-

scribed in this chapter.

16. Connect the negative battery cable as described

in Chapter Eight.

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CLUTCH AND PRIMARY DRIVE

223

STARTER JACKSHAFT

98

Refer to Figure 95.

Removal

NOTE

On models so equipped, always dis-

arm the optional TSSM security sys-

tem prior to disconnecting the battery

or the siren will sound.

5

1. Disconnect the negative battery cable as de-

scribed in Chapter Eight.

99

2. Remove the primary chaincase outer cover as

described in this chapter.

NOTE

If only removing parts 1-5 listed in

Figure 95, do not perform Step 3.

3. Remove the compensating sprocket, primary

chain and clutch assembly as described in this chap-

ter.

4. Straighten the tab on the lockplate (Figure 96).

5. Wrap the pinion gear with a cloth to protect the

finish, then secure it with locking pliers (A, Figure

100

97).

6. Loosen and remove the bolt (B, Figure 97),

lockplate and thrust washer from the starter

jackshaft assembly and the end of the starter motor.

7. Remove the pinion gear (Figure 98) from the

jackshaft.

8. Remove the jackshaft assembly (Figure 99)

from the inner housing.

CAUTION

Do not remove the coupling (Figure

100) through the oil seal in the inner

cover. If removed, the oil seal will be

101

damaged.

9. To remove the coupling (Figure 100), remove

the starter motor as described in Chapter Eight, then

remove the coupling.

Inspection

1. Clean the jackshaft assembly (Figure 101) in

solvent and dry with compressed air.

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224

CHAPTER FIVE

102

103

2. Check the snap ring installed in each coupling

(Figure 102 and Figure 103). Replace any loose or

104

damaged snap rings.

3. Replace all worn or damaged parts.

Installation

NOTE

Before installing the coupling in Step

4, note the snap ring (Figure 102) in-

stalled inside the coupling. The cou-

pling side with the snap ring closest to

its end slides over the jackshaft.

1. If removed install the coupling (Figure 100) and

105

then the starter motor as described in Chapter Eight.

2. Install the coupling (A, Figure 104) onto the

jackshaft

(B, Figure

104) with the coupling’s

counterbore facing toward the jackshaft (Figure

105).

3. Install the jackshaft into the inner housing (Fig-

ure 99) and push it in until it bottoms (A, Figure

106).

4. Install the spring

(B, Figure

106) onto the

jackshaft.

5. Install the bolt (A, Figure 107), lockplate (B),

thrust washer (C) and pinion gear (D) onto the

106

jackshaft.

6. Push the assembly on until it bottoms.

7. Align the lockplate tab with the thrust washer,

then insert the tab into the notch in the end of the

jackshaft.

8. Screw the bolt into the starter motor shaft by

hand.

9. Wrap the pinion gear with a cloth to protect the

finish, then secure it with locking pliers (A, Figure

97).

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CLUTCH AND PRIMARY DRIVE

225

107

111

5

10. Tighten the bolt (B, Figure 97) onto the starter

108

motor to the specification in Table 2. Bend the outer

lockplate tab against the bolt head (Figure 96).

11. To ensure that all components have been in-

stalled correctly, perform the following:

a. Install the clutch shell (Figure 108) onto the

transmission mainshaft.

b. With the starter motor not engaged, the pinion

gear (A, Figure 109) must not engage the

clutch shell gear (B, Figure 109).

c. To check for proper engagement, pull out on

the pinion gear (A, Figure 109) and engage it

with the clutch shell gear (B, Figure 109).

Then rotate the clutch shell in either direction

109

(Figure 110) and make sure the pinion gear

rotates with it.

d. If engagement is incorrect, remove the clutch

shell and correct the problem.

e. Remove the clutch shell.

12. Install the compensating sprocket, primary

chain and clutch assembly as described in this chap-

ter.

13. Install the primary chaincase outer cover as de-

scribed in this chapter.

14. Connect the negative battery cable as described

in Chapter Eight.

110

CLUTCH CABLE

REPLACEMENT

1. Before removing the clutch cable, make a draw-

ing of its routing path from the handlebar to the

transmission side door.

2. Disconnect the clutch cable from the clutch re-

lease mechanism (Figure 111) as described under

Transmission Side Cover in Chapter Six.

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226

CHAPTER FIVE

112

114

113

115

3. Remove the snap ring from the base of the clutch

8. Route the new clutch cable from the handlebar to

lever pivot pin.

the transmission side cover, following the drawing

made in Step 1.

4. Remove the pivot pin (Figure 112) and slide the

9. Fit the clutch cable into its lever and secure with

clutch lever out its perch.

the plastic anchor pin (Figure 113).

5. Remove the plastic anchor pin (Figure 113) and

10. Slide the clutch lever into the perch and install

disconnect the clutch cable from the lever.

the pivot pin (Figure 112).

11. Secure the pivot pin with the snap ring.

6. Check the clutch lever components (Figure 114)

12. Reconnect the clutch cable to the clutch release

for worn or damaged parts.

mechanism as described under Transmission Side

7. Check that the anti-slack spring screw (Figure

Cover in Chapter Six.

115) on the bottom of the clutch lever is tight.

13. Adjust the clutch as described in Chapter Three.

Table 1 CLUTCH SPECIFICATIONS AND SPROCKET SIZES

Item

Specification

Clutch type

Wet, multiplate disc

Clutch lever free play

1/16-1/8 in. (1.6-3.2 mm)

Clutch friction plate thickness

Service limit

0.143 in. (3.62 mm)

Clutch plate warpage

Service limit

0.006 in. (0.15 mm)

Compensating sprocket

25 teeth

Clutch sprocket

36 teeth

Transmission sprocket

32 teeth

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TRANSMISSION

229

1

SHIFTER ASSEMBLY (1999-2000)

6

1. Bolt

18. Spring

31. Retainer (except

2. Washer

19. Shift fork shaft

FXDWG)

3. Snap ring

20. No. 3 shift fork

32. Inner shift lever (except

4. Thrust washer

21. No. 2 shift fork

FXDWG)

5. Needle bearing

22. No. 1 shift fork

33. Wave washer (except

6. Shift drum

23. Set screw

FXDWG)

7. Needle bearing

24. Shift rod (FXDWG)

34. O-ring (except FXDWG)

8. Support-left side

25. Inner shift lever

35. Shift lever sleeve

9. Bolt

(FXDWG)

(except FXDWG)

10. Roll pin

26. Sleeve bearings

36. Adjust screw

11. Cam follower

(FXDWG)

37. Locknut

12. Spring

27. Outer shift lever

38. Shift rod lever

13. Shift cam pawl

28. Cover

39. Transmission case

14. Shift shaft lever

29. Shift rod (except

40. Support-right side

15. Spring

FXDWG)

41. Oil seal

16. Pin

30. Acorn nut (except

42. Nut

17. Centering plate

FXDWG)

(Chapter Three) can generally fix minor clutch prob-

sembly connects the transmission shifter rod lever

lems. If the shifter linkage or adjuster is out of adjust-

to the foot-operated shift lever. The shift linkage ad-

ment, perform the following procedure. Make sure to

justment does not require adjustment unless the

eliminate all clutch or shifter mechanism problems

shift linkage is replaced or the transmission gears do

before assuming a problem is in the transmission.

not engage properly.

Refer to Figure 1 (1999-2000 models), Figure 2

(2001 models except FXDP) and Figure 3 (FXDP

NOTE

On models so equipped, always dis-

models).

arm the optional TSSM security sys-

tem prior to disconnecting the battery

or the siren will sound.

Shift Linkage Adjustment

The shift linkage assembly consists of the shift

1. Disconnect the negative battery cable as de-

linkage rod and two ball joints. The shift linkage as-

scribed in Chapter Eight.

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230

CHAPTER SIX

2

SHIFTER ASSEMBLY (2001 EXCEPT FXDP)

28. Cover

29. Shift rod (except FXDWG)

15. Spring

30. Acorn nut (except

16. Pin

FXDWG)

1. Bolt

17. Centering plate

31. Retainer (except FXDWG)

2. Washer

18. Spring

32. Inner shift lever (except

3. Shift cam

19. Shift fork shaft

FXDWG)

4. Snap ring

20. No. 3 shift fork

33. Wave washer (except

5. Ball bearing

21. No. 2 shift fork

FXDWG)

6. Support-right side

22. No. 1 shift fork

34. O-ring (except FXDWG)

7. Support-left side

23. Set screw

35. Shift lever sleeve (except

8. Dowel pin

24. Shift rod (FXDWG

FXDWG)

9. Detent follower

models)

36. Adjust screw

10. Sleeve

25. Inner shift lever (FXDWG

37. Locknut

11. Spring

models)

38. Shift rod lever

12. Pivot screw

26. Sleeve bearings (FXDWG

39. Transmission case

13. Shift cam pawl*

models)

40. Oil seal

14. Shift shaft lever

27. Outer shift lever

41. Nut

*See Figure 139 and Figure 140 for details

2. Loosen the two shift linkage rod locknuts (A,

cedure if there are no visible interference problems

Figure 4).

or damage.

3. Remove the acorn nut, washers and bolt (B, Fig-

ure 4) securing the shift linkage rod to the inner

Gear Engagement Check/Adjustment

shift lever.

(1999-2000 Models Only)

4. Turn the shift linkage rod (C, Figure 4) as neces-

sary to change the linkage adjustment.

If the transmission gears do not engage properly,

5. Tighten the locknuts and reconnect the shift link-

check and adjust gear engagement as follows:

age rod to the shift lever.

NOTE

6. Recheck the shifting. Readjust if necessary.

The 2001 models do not require this

7. If proper shifting cannot be obtained by per-

check and adjustment procedure.

forming this adjustment, check the shift linkage for

any interference problems. Then check the shift

1. Make sure the clutch is working properly. Refer

linkage assembly for worn or damaged parts. Per-

to clutch adjustment in Chapter Three. If the clutch

form the Gear Engagement Check/Adjustment pro-

is working properly, continue with Step 2.

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TRANSMISSION

231

3

SHIFTER ASSEMBLY (2001 FXDP)

6

1. Bolt

15. Spring

29. Shift rod

2. Washer

16. Pin

30. Inner shift lever

3. Shift cam

17. Centering plate

31. Wave washer

4. Snap ring

18. Spring

32. Bushing

5. Ball bearing

19. Shift fork shaft

33. Shift lever plate

6. Support-right side

20. No. 3 shift fork

34. Grease fitting

7. Support-left side

21. No. 2 shift fork

35. Acorn nut

8. Dowel pin

22. No. 1 shift fork

36. Bolt

9. Detent follower

23. Set screw

37. Bushing

10. Sleeve

24. Transmission case

38. Outer shift lever

11. Spring

25. Adjust screw

39. Cover

12. Pivot screw

26. Locknut

40. Set screw

13. Shift cam pawl*

27. Oil seal

14. Shift shaft lever

28. Shift lever

*See Figure 139 and Figure 140 for details

NOTE

4

On models so equipped, always dis-

arm the optional TSSM security sys-

tem prior to disconnecting the battery

or the siren will sound.

2. Disconnect the negative battery cable as de-

scribed in Chapter Eight.

3. Shift the transmission into third gear. Make sure

third gear is fully engaged.

4. Remove the transmission top cover as described

in this chapter.

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232

CHAPTER SIX

5

6

0.010 in.

0.010 in.

(0.25 mm)

(0.25 mm)

Shift pawl

Shift cam

Cam pins (4)

5. Move the shift shaft pawl (Figure 5) to check for

free play and spring pressure in both directions. Gear

engagement is correct if the spring pressure is the

same in both directions and with approximately 0.10

in. (0.25 mm) clearance between the shift pawl arms

and the shift cam pins (Figure 6). If necessary, adjust

7

gear engagement as described in Step 6.

NOTE

An incorrectly adjusted shift pawl

causes many shifting-related prob-

lems.

6.

To adjust the gear engagement, follow these steps:

a. The shifter pawl adjuster is mounted on the

left-hand side of the transmission case (Figure

7). It is between the transmission case and pri-

mary chain housing. Figure

8 shows the

shifter pawl adjusting screw and locknut with

the inner primary housing removed for clarity.

8

b. Use the transmission pawl adjuster (part No.

HD-39618) to adjust the shifter pawl adjuster.

Locknut

Adjuster

c. Loosen the adjuster screw locknut (Figure 8)

and turn the shifter pawl adjuster in 1/4 turn

(or less) increments

(either clockwise or

counterclockwise). Turn the screw until the

shifter lever travel spring pressure is equal on

both sides while maintaining a clearance of

0.010 in. (0.25 mm). Tighten the locknut and

recheck the adjustment.

7.

Reinstall the transmission top cover as described

in this chapter.

8.

Reconnect the negative battery cable.

TRANSMISSION TOP COVER

Shift arm shaft

The transmission top cover assembly can be ser-

viced with the transmission installed in the frame.

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TRANSMISSION

233

6. Remove the gasket residue from the transmis-

9

sion cover and transmission case gasket surfaces.

7. Install a new gasket (Figure 11) onto the trans-

mission case.

8. Install the transmission top cover, bolts and

washers. Tighten the bolts in a crisscross pattern to

the specification in Table 3.

9. Reconnect the hoses to the fittings and install

new hose clamps.

10. Install the transmission oil dipstick.

11. Connect the wire to the neutral indicator switch

(Figure 9).

12. Install the rear exhaust pipe or entire exhaust

system as described in Chapter Seven.

10

6

SHIFTER CAM

(1999-2000)

The shifter cam mounts on top of the transmis-

sion case, underneath the transmission top cover.

The shifter cam assembly can be serviced with the

transmission installed in the frame.

Refer to Figure 12.

Removal

1. Remove the transmission top cover as described

11

in this chapter.

2. Remove the shifter cam support block mounting

bolts and lockwashers.

3. Carefully lift the shifter cam assembly up and

out of the transmission case.

4. Remove the four dowel pins from the transmis-

sion case.

Installation

1. Install the four dowel pins into the transmission

Removal/Installation

case.

2. Measure shifter cam end play as follows:

1. Remove the rear exhaust pipe or entire exhaust

a. Position the left support block with the num-

system as described in Chapter Seven.

bers facing down toward the transmission

2. Disconnect the wire from the neutral indicator

case.

switch (Figure 9).

b. Install the shifter cam/support block assem-

3. Remove the transmission oil dipstick.

bly onto the transmission case. Align the shift

4. Disconnect the hoses (A, Figure 10) from the

fork pins with the shifter cam slots.

top cover or their fittings.

c. Use a flat feeler gauge (A, Figure 13) and

5. Remove the bolts and washers securing the

measure the clearance between the outer

transmission cover to the transmission case. Re-

thrust washer and the shifter cam (B, Figure

move the top cover (B, Figure 10) and the gasket.

13). This clearance is shifter cam end play.

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234

CHAPTER SIX

12

SHIFT CAM ASSEMBLY (1999-2000)

1. Shift cam

2. Needle bearing

3. Support block-left side

4. Snap ring

5. Outer thrust washer

6. Support block-right

side

7. Cam follower

8. Spring

9. Roll pin

Refer to Table 2 for the end play measure-

ment.

13

d. To correct end play, replace the outer thrust

washer (Figure 12) with a suitable thickness

thrust washer.

NOTE

Inner and outer thrust washers are

available from Harley-Davidson deal-

ers in the following thicknesses: 0.017,

0.020,

0.022,

0.025,

0.028,

0.031,

0.035 and 0.039 in. (0.43, 0.51, 0.56,

0.63, 0.71, 0.79, 0.89 and 0.99 mm).

e. If necessary, remove the shifter cam assembly

from the transmission case and install a new

outer thrust washer.

3. Apply engine oil to the shifter cam bearing sur-

14

faces.

4. Align the shift fork pins with the shifter cam

slots and install the shifter cam into position (Fig-

ure 14).

5. Engage the shifter pawl with the shifter cam

(Figure 15).

CAUTION

Do not overtighten the shifter cam

mounting bolts as this can distort the

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TRANSMISSION

235

15

19

cam follower and cause shifting prob-

16

lems. Do not exceed the torque speci-

6

fication in Step 6.

6. Install the shifter cam support block mounting

bolts and lockwashers. Tighten in a crisscross pat-

tern to the specification in Table 3.

7. Perform the Gear Engagement Check/Adjust-

ment in this chapter.

8. Install the transmission top cover as described in

this chapter.

Disassembly

1. Slide the left side support block (Figure 16) off

17

the shifter cam.

2. Remove the shifter cam snap ring (A, Figure 17)

and the outer thrust washer (B, Figure 17).

3. Remove the right side support block (Figure

18).

Inspection

1. Clean all parts except the support block bearings

in solvent and thoroughly dry.

2. Check the shifter cam grooves (Figure 19) for

wear or roughness. Replace the shifter cam if the

18

groove profiles show excessive wear or damage.

3. Check the shifter cam ends where the cam con-

tacts the bearings. If the ends show wear or damage,

replace the shifter cam and both support block bear-

ings. Refer to Support Block Bearing Replacement

in this chapter.

4. Check the support block bearings for excessive

wear, cracks, or other damage. See Figure 20 and

Figure 21. If necessary, refer to Support Block

Bearing Replacement in this chapter to replace the

bearings.

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236

CHAPTER SIX

20

21

22

SHIFT CAM ASSEMBLY (2001)

1. Snap ring

2. Ball bearing

3. Support-right side

4. Shift cam

5. Support-left side

6. Snap ring

7. Detent follower

8. Sleeve

9. Spring

10. Pivot screw

5. Check the support blocks for wear, cracks or

NOTE

other damage. Replace the support blocks if neces-

After installing the snap ring, make

sary.

sure the outer thrust washer can be

rotated by hand.

Assembly

4. Install the left support block (Figure 16) onto

the shifter cam.

5. Rotate the support blocks so their numbered side

1. Coat all bearing and sliding surfaces with assem-

is facing down.

bly oil.

2. Install the right support block (Figure 18) on the

Support Block Bearing Replacement

shifter cam.

3. Install the outer thrust washer (B, Figure 17) and

Each support block is equipped with a single nee-

a new snap ring (A, Figure 17). Make sure the snap

dle bearing. See Figure 20 and Figure 21. Replace

ring seats in the shifter cam groove.

both bearings at the same time. The removal and in-

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TRANSMISSION

237

23

25

24

6

5. Remove the four dowel pins from the transmis-

sion case.

Installation

stallation of the bearings requires a press. Refer to

1. Install the four dowel pins into the transmission

Bearing Replacement in Chapter One. Before re-

case.

moving the bearings, record the direction in which

2. Lift the shifter cam pawl up out of the way.

the bearing manufacturer’s marks face for proper

installation.

3. Carefully install the shifter cam assembly into

the transmission case. Align the shifter fork pins

with the shifter cam slots (Figure 24).

SHIFTER CAM (2001)

4. Lower the shifter cam pawl and engage it with

the cam pins.

The shifter cam mounts on top of the transmis-

5. Install the shifter cam support block mounting

sion case, underneath the transmission top cover.

bolts and lockwashers (Figure 23). Tighten in a

The shifter cam assembly can be serviced with the

crisscross pattern to the specification in Table 3.

transmission installed in the frame.

6. Install the transmission top cover as described in

Refer to Figure 22.

this chapter.

Removal

Disassembly

1. Remove the transmission top cover as described

in this chapter.

1. On the right side, perform the following:

2. Remove the shifter cam support block mounting

a. Slide the right side support block (A, Figure

bolts and lockwashers (Figure 23).

25) off the shifter cam.

3. Lift the shifter cam pawl off the cam pins to free

b. Remove the retaining ring (B, Figure 25) and

the assembly.

withdraw the bearing (C, Figure 25) from the

4. Carefully lift the shifter cam assembly up and

support block.

out of the transmission case.

2. On the left side, perform the following:

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238

CHAPTER SIX

26

27

a. Remove the small retaining ring (A, Figure

Assembly

26) from the shifter cam.

b. Slide the left side support block (B, Figure

1. Coat all bearing and sliding surfaces with assem-

26) off the shifter cam.

bly oil.

c. Remove the large retaining ring (C, Figure

2. To install the detent follower, perform the fol-

26) and withdraw the bearing from the sup-

lowing:

port block.

a. Slide the spring sleeve (C, Figure 27) into the

3. To remove the detent follower, unscrew the pivot

spring (B).

bolt (A, Figure 27). Remove the spring (B), spring

b. Insert the pivot bolt (A) through the spring

sleeve (C) and the detent follower (D).

and sleeve.

c. Correctly position the detent follower onto

the bolt and place the spring end over the

Inspection

detent follower.

d. Install the assembly onto the right side sup-

1. Clean all parts except the support block bearings

port and insert the spring’s other end into the

in solvent and dry thoroughly.

receptacle in the right side support. Screw the

2. Check the shifter cam grooves (Figure 19) for

bolt into place and tighten to the specification

wear or roughness. Replace the shifter cam if the

in Table 3.

groove profiles show excessive wear or damage.

3. Check the shifter cam ends where the cam con-

3. On the left side, perform the following:

tacts the bearings. If the ends show wear or damage,

a. Position the bearing with the manufacturer’s

replace the shifter cam and both support block bear-

numbers facing out. Install the bearing into

ings; see Support Block Bearing Replacement in

the support block.

this chapter.

b. Position the new large retaining ring (C, Fig-

4. Check the support block bearings for excessive

ure 26) so the larger tab will be on the right

wear, cracks, or other damage. See Figures 20 and

side when looking at the end of the support

21. If necessary, refer to Support Block Bearing Re-

block. Install the large retaining ring.

placement in this chapter to replace the bearings.

c. Make sure the retaining ring is correctly

5. Check the support blocks for wear, cracks or

seated in the groove.

other damage. Replace the support blocks if neces-

d. Slide the left side support block (B, Figure

sary.

26) onto the shifter cam.

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TRANSMISSION

239

Shift shaft

28

30

No. 2

No. 1

No. 3

No. 1

No. 2

No. 3

6

Front

SHIFT FORKS

29

The shift forks are installed at the top of the trans-

mission case, underneath the shifter cam. The shift

forks can be serviced with the transmission installed

in the frame.

Refer to Figure 1 (1999-2000 models), Figure 2

(2001 models except FXDP) and Figure 3 (FXDP

models).

Removal

e. Install a new small retaining ring (A, Figure

1. Remove the shifter cam as described in this

26) onto the shifter cam.

chapter.

f. Make sure the small retaining ring is correctly

seated in the groove.

2. Remove the transmission side cover as de-

scribed in this chapter.

4.

On the right side, perform the following:

a. Position the bearing with the manufacturer’s

NOTE

numbers facing out. Install the bearing into

Use a waterproof felt-tip pen or scribe

the support block.

to mark the installed position of each

b. Position the new retaining ring (B, Figure 25)

shift fork as it sits in the transmission

with the beveled side facing out when looking

(Figure 28). All three shift forks are

at the end of the support block. Install the

unique and must be reinstalled in the

large retaining ring.

correct position.

c. Make sure the retaining ring is correctly

seated in the groove.

3. Slide the shift shaft (A, Figure 29) out of the

d. Slide the right side support block (A, Figure

transmission case and remove the shift forks (Fig-

25) onto the shifter cam.

ure 30) from the transmission case.

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