5 speed trans question...
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Joined: Aug 2016
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From: Colorado Springs
Let me understand this clearly, the transmission worked fine till you put this new primary belt drive on? What belt drive did you install? I'm pretty sure both 4th gears should be lined up evenly. I'm thinking the nut backed out on the main shaft at the Trap door. or possibly when you torqued the clutch basket nut maybe you might have pulled the main shaft towards the clutch basket. I think you're going to need to pull the clutch release cover and take a look at the ends of both the counter and main shaft. The nuts they should be even with each other in the trapdoor... Post a pick of the trap door end showing both shafts and nuts...
GRRRRRRRRRRR ****! AGHHHHHHHH.
So either when I pulled the clutch basket off after the test fit for alignment without the 3 jaw puller on there and yanked it out of it's socket AGAIN! or something else did it and it'll happen again.
Either way, some tippy tappy with a block of wood and some gentle yet loving hammer blow in the center and everything went back in and lined up perfectly:
Including 4th GEAR (Upside down, sorry about that)!
This'll hopefully be the 3rd and LAST time I have to bleed this damn thing! But on the bright side I get to fill the trans from the top this time!
Last edited by avenger09123; Jun 10, 2019 at 11:42 PM.
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From: Poolville
I have a gear set in a trap door at the shop I'll take a look at if I can get there today. But I believe that bearing goes in from the clutch cover side, that's why the clip is there it's a retainer and I believe there's also a lip on the inside of that trap door that holds that bearing in position. You might have to lock the transmission into two gears and take two nuts off the main shaft and countershaft and pull the circlips and pull the trap door off the shafts and inspect the backside of that trapdoor...
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From: Farmington ,MS
I have a gear set in a trap door at the shop I'll take a look at if I can get there today. But I believe that bearing goes in from the clutch cover side, that's why the clip is there it's a retainer and I believe there's also a lip on the inside of that trap door that holds that bearing in position. You might have to lock the transmission into two gears and take two nuts off the main shaft and countershaft and pull the circlips and pull the trap door off the shafts and inspect the backside of that trapdoor...
You need a new trap door...it should not be possible for the bearing to move in that direction...
you also need to inspect your hydraulic clutch...something broke that lip
Last edited by Tom84FXST; Jun 11, 2019 at 07:37 AM.
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From: South Carolina
You need to remove the entire gearset, remove the shafts from the bearings, throw the trap door into the scrap bin and get another trapdoor and new bearings.
And tell us the model and year bike you are working on.
And tell us the model and year bike you are working on.
Last edited by Dan89FLSTC; Jun 11, 2019 at 07:53 AM.
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From: Poolville
That's exactly what I suspected... Thanx for the pic, Tom.... saves me a trip to the shop....
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From: Colorado Springs
Bike is a 1996 FLHT.
Well thank you guys, you have cost me about $100 in additional tools and an oem trapdoor probably from fleabay with new bearings and whatnot, but probably saved my skin from an encounter with the roadway and a new transmission gearset all together.
So I guess there are tools out there to remove the trapdoor without removing the gearset, and a tool in particular from Georges to pull the shafts back into the center races and brace them at the same time, so thats probably what Im gonna do. Obviously goal is to not have to remove the gearset or the primary side.
That being said. Clearly I have a lifetime of bad coping mechanisms that gave me the inner and outer strength to overcome that lip by squeezing the clutch lever with all my might like a dumbass, but I appreciate your help on diagnosing this issue, again the trans is the ONE thing I havent torn completely down yet and therefore know very little about. Expensive lesson. The hydraulic clutch itself is fine, I ordered new seals and replaced the existing slaves seals and all is well. Currently everything is properly spaced so I should not run into this issue again and if I do for some reason I know what NOT to do.
Well thank you guys, you have cost me about $100 in additional tools and an oem trapdoor probably from fleabay with new bearings and whatnot, but probably saved my skin from an encounter with the roadway and a new transmission gearset all together.
So I guess there are tools out there to remove the trapdoor without removing the gearset, and a tool in particular from Georges to pull the shafts back into the center races and brace them at the same time, so thats probably what Im gonna do. Obviously goal is to not have to remove the gearset or the primary side.
That being said. Clearly I have a lifetime of bad coping mechanisms that gave me the inner and outer strength to overcome that lip by squeezing the clutch lever with all my might like a dumbass, but I appreciate your help on diagnosing this issue, again the trans is the ONE thing I havent torn completely down yet and therefore know very little about. Expensive lesson. The hydraulic clutch itself is fine, I ordered new seals and replaced the existing slaves seals and all is well. Currently everything is properly spaced so I should not run into this issue again and if I do for some reason I know what NOT to do.
Last edited by avenger09123; Jun 11, 2019 at 12:20 PM.
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From: Farmington ,MS
So I guess there are tools out there to remove the trapdoor without removing the gearset, and a tool in particular from Georges to pull the shafts back into the center races and brace them at the same time, so thats probably what Im gonna do. Obviously goal is to not have to remove the gearset or the primary side.
Yep, you can spend the bucks and buy fancy tools to pull the trap door with out pulling the gear set...but you have metal in the trans(the broken trap door lip...so I would save the bucks, and pull the gear-set, so you can clean out the case...it is not that much more work...use the money you saved and go ahead and replace all the bearings and seals while you have it apart...
Last edited by Tom84FXST; Jun 11, 2019 at 01:43 PM.
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Seasoned HDF Member
Joined: May 2008
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From: South Carolina
You had no reservations about a bearing out of position, so you tapped it back into place with a mallet...
I`m going to say that you have little understanding of shafts, bearings etc, let alone transmissions.
You need to remove the entire gearset, by following the factory service manual, a shortcut by and inexperienced mechanic can get ugly fast.
I`m going to say that you have little understanding of shafts, bearings etc, let alone transmissions.
You need to remove the entire gearset, by following the factory service manual, a shortcut by and inexperienced mechanic can get ugly fast.
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From: Poolville
you should do what Tom said, because with all that Force to break out the trapdoor what kind of pressure did you put on the 5th gear bearing as well you should remove the pulley check the bearing. Everything in that area, there's circlip that holds that 5th gear bearing in also and a thin lip on the inside of the case that you should check also..