Bagga, thanks for the heads up. It passes the finger nail test. That was my concern when I got things all cleaned up and discovered the issue. The only thing I can think of that caused this is the nut moved despite the locking plate being firmly in place. It obviously wore the locking plate peaked tabs and wore away the nut. The only other thing I can think of is belt to tight?

Main shaft and counter shaft nuts just got snugged up. Really did not have much movement with the torque wrench set at 48 lbs but they did move. I got lucky and only had to loosen the exhaust instead of having to remove it.

Hope to start putting things back together this weekend. YD

 

did you pull the spacer out to do the finger nail test?

 

Yes sir, sure did, but thanks for double checking.

 

by the looks of the splines in the pic they don't look good. it looks like there is wear right were the spacer ends. what did the pulley splines look like?

 

Measurements of 5th gear spline sprocket area and then virgin splines under the spacer. Shaft OD at the sprocket area are 1.6950 and at virgin area under spacer 1.7000

I have a previous pic in this thread showing sprocket splines. I do have a new sprocket to go on. YD

 

did you fingernail the sides of the splines? that's where the problem wear happens... not the OD.

 

I have to disagree with the term "normally".

The race is certainly known to walk on the shaft, but it does not normally happen.

 

Ok, it's Common....
I would like to see better pictures of that fifth gear also of the race and the input shaft as well. Are you replacing the ipb...

 

Baker high torque bearing.

I had a few buddies with more experience with this than me look at it and they say "ain't bad"...but then again their bikes leak...

The 5th gear issue, it is what it is. I have to get this bike together. I have a couple unexpected issues and some deadlines come up. I also need my garage back. I did a brake job in the rain today, and I have a cement crew coming to tear out my driveway and install new any day now. I have other obligations to meet, (mom is 80 years old and health has taken a turn for the worse this past Wednesday) and I am not leaving this bike apart while tending to her or while I have a cement crew in and out of my garage.

Normally, I would take your word for it and just replace the 5th gear because of the questionable appearance. But not now. It's going back together and I will deal with it this winter. I have no choice but to gamble. This has snowballed on me and kind of caught me off guard. I just can't leave this bike apart any longer. I know it's twice as much work, but I'm OK with it.

I am grateful for all the help, and am not trying to disrespect anybody by not following any advice. It is simply I am running out of time. This winter I will go through it, take my time, replace 5th gear, bearings, anything else that needs attention. I took measurements today so I can take my time making the tools to press out and install 5th gear and bearing and anything else I might need for this winter.

After I get it back together (hopefully tomorrow), I will mark the nut so I can keep an eye on it. I put in the new seals and spacer (late 94 and later) today, shift shaft seal, jackshaft seal. Cleaned bolts. threads, etc. Have engine, trans, and primary pretty close to proper alignment now. Sprocket going on tonight or in the morning. Using harley's updated torque to 50 ft lbs, then an additional 30 to 40 degrees. Locking the gears in the tranny prior to torque. Then it's a matter of putting the replacement inner primary on. YD

 

if the fifth gear is shot and the new pulley wobbles because of the splines it will leak like a **** and you might have to go with another new pulley when you redo it. having said that.... it's your bike do as you wish.