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If you use that gearset you should also use the shift pawl and shift drum that are with it, they are the late model hardware.
You will have to either replace the shifter shaft bushing in the transmission case or use a spacer.
Also, when you reassemble, if you are still running the original transmission sprocket you should replace it with the upgraded sprocket, spacer, and lock setup (these parts came out in mid `95).
The parts may still be available as a kit, HD part number 40210-85D.
Individual Part Numbers:
Sprocket (pulley) 40250-94C
Spacer 33344-94
Nut 35211-91B
Lock plate 40251-92A
Screw (2) 3594
Oil Seal 12067B
Quad Seal 11165
Oil Seal, main drive gear 12035B
By "Upgraded Sprocket" are you referring to the front pulley?
I did order the gear set in the pics. They offered a discount and couldn't pass it up. All are from a 2004 with just over 14k mi. I also ordered a new steel pulley. Any issue with the original style pulley mating with main shaft on new gear set? I wanted to get all parts here this week as I have next week off and plan on reassembling as much as possible.
Now for the shifter shaft bushing. The new bushing is $20. No problem. But the tool is $60? Should I just cut a 1/4" length from new bushing make a spacer? Is the tool necessary?
Then on to the Neutral switch. I would like it functional. Do I need a later style switch? Will my original top cover work?
With the late model gear set and shifter components, is it true I will need a late model trans top cover and neutral switch? Started the research this morning, but alas I had to get to work to be able to pay for these mods. All feedback is very much appreciated!
With the late model gear set and shifter components, is it true I will need a late model trans top cover and neutral switch? Started the research this morning, but alas I had to get to work to be able to pay for these mods. All feedback is very much appreciated!
I see the later model Neutral switch and cable are being sent along with the gear set I purchased. I researched the top cover P/N's and they are indeed different between the '91 and '04 model years.
So I assume I will need to source a dif top cover to locate the switch properly? Then wire it in proper.
Is there a dif between:
34541-00 and 34543-00 Top covers? The 34543-00 are more readily available and much cheaper to get in used condition. Was it just a P/N change possibly?
Last edited by DeputyLoud; Apr 6, 2022 at 09:54 AM.
Well we all lost that bet. Sprocket/Pulley is fine unfortunately. Gear set is coming out next for review. Could it possibly be an issue on the compensating sprocket? Or internal issue with that on the motor side?
Confused. Gear set seems ok too. Where's all the metal shavings or broken components? Waiting for the obvious to appear.
1) I do not understand the compensating sprocket assy ops.
2) Maybe I should go back and review the clutch plate assy. My measurements seemed good tho.
Last edited by DeputyLoud; Apr 9, 2022 at 02:10 PM.
Honestly I never really fully understood what your situation is.. For some reason I was a little confused... if you're pully and gear set and 5th gear is fine there's no reason why you shouldn't be transferring power to the rear wheel unless that is you blew your clutch basket..
Now that you're into a little bit what exactly is happening.. what exactly what's going on...?
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