Transmission Issue
Road Warrior
Joined: Dec 2012
Posts: 1,539
Likes: 692
From: magnolia tx
Dan is correct, you have to use the 2004 main gear "5th" the 2004 main shaft will not go all way into a 90's main gear, the spacer is also different and seal, outside dia of seal is the same, the 2004 inside dia is larger, if you use the 2004 main shaft spacer and seal you will have to use the newer style front sprocket, but you can use the old style spacer and seal on the 2004 main shaft and use your original sprocket, just not as good of a sprocket as newer style
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Dan is correct, you have to use the 2004 main gear "5th" the 2004 main shaft will not go all way into a 90's main gear, the spacer is also different and seal, outside dia of seal is the same, the 2004 inside dia is larger, if you use the 2004 main shaft spacer and seal you will have to use the newer style front sprocket, but you can use the old style spacer and seal on the 2004 main shaft and use your original sprocket, just not as good of a sprocket as newer style
https://kcint.com/for-harley-softail...t-60-pk-378-06
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Dan is correct, you have to use the 2004 main gear "5th" the 2004 main shaft will not go all way into a 90's main gear, the spacer is also different and seal, outside dia of seal is the same, the 2004 inside dia is larger, if you use the 2004 main shaft spacer and seal you will have to use the newer style front sprocket, but you can use the old style spacer and seal on the 2004 main shaft and use your original sprocket, just not as good of a sprocket as newer style
Road Warrior
Joined: Dec 2012
Posts: 1,539
Likes: 692
From: magnolia tx
Hoping this front sprocket I ordered is of the updated design? Haven't received it yet but could return it if needed. Has anyone used these?
https://kcint.com/for-harley-softail...t-60-pk-378-06
https://kcint.com/for-harley-softail...t-60-pk-378-06
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Oh and I now have the new gear set which includes the shaft spacer. Can measure with the one from 91 to compare.
Seasoned HDF Member
Joined: May 2008
Posts: 21,032
Likes: 12,559
From: South Carolina
40210-85D is the HD part number for the kit with the updated sprocket components.
If a spacer is not included, just use an OEM for `95 or later.
Don`t reuse the spacer, get a new one.
If a spacer is not included, just use an OEM for `95 or later.
Don`t reuse the spacer, get a new one.
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Last edited by DeputyLoud; Apr 12, 2022 at 08:32 PM.
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
So in lue of parts deliveries, today was a good day to disconnect swing arm and get new belt in place. Cleaned up 30 yrs of road grime, sand and gravel on frame. Glad thats done.
Read something interesting that got me thinking. And honestly thus far it makes the most sense. It says to check belt tension a few times after certain milestones. A loose belt will jump sprocket teeth and could lead to a stripped belt.
Not last year, didn't get much riding in, but the end of the season before I took my rear wheel in for new tire install. I've had the wheel off before, so I've set the belt tension before. But just maybe this last time I was a little light on the tension and I failed to check it after riding. Plus it recommends setting tension with a rider in place on the bike.
That coupled with an old belt, I could see after the first few teeth were stripped off it just compounded from there. It's a theory.
Read something interesting that got me thinking. And honestly thus far it makes the most sense. It says to check belt tension a few times after certain milestones. A loose belt will jump sprocket teeth and could lead to a stripped belt.
Not last year, didn't get much riding in, but the end of the season before I took my rear wheel in for new tire install. I've had the wheel off before, so I've set the belt tension before. But just maybe this last time I was a little light on the tension and I failed to check it after riding. Plus it recommends setting tension with a rider in place on the bike.
That coupled with an old belt, I could see after the first few teeth were stripped off it just compounded from there. It's a theory.
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Oh and to my surprise I received the new shifter pawl today. I knew it was shipping from same state of WI, but damn that was fast. Happy to find it was also a fully sealed oem harley pawl. Ebay pic showed it out of package with the small spring separated. Things are lookin up.
And even tho the root cause that prompted this tear down is mostly unknown, I feel confident in all the theories proposed, and do not regret the decisions made thus far. All these new components should outlast me and the rest of my riding career.
I also want to Thank everyone here again for all the help and support. You guys are Top Notch!
And even tho the root cause that prompted this tear down is mostly unknown, I feel confident in all the theories proposed, and do not regret the decisions made thus far. All these new components should outlast me and the rest of my riding career.
I also want to Thank everyone here again for all the help and support. You guys are Top Notch!
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Finally feel like I'm making progress again. Received and installed main bearing, Main gear, countershaft needle bearing, and shifter pawl. Took the time to clean off all old gaskets. Should I use any gasket sealer at all when installing new gaskets? I don't see any evidence of that from mfg assy. But they sure were baked on there.
And to my surprise the main bearing came out very easily. As I was installing the bearing puller tool it popped out by hand. Same when installing new main bearing. Slipped right in as soon as it was aligned properly.
And to my surprise the main bearing came out very easily. As I was installing the bearing puller tool it popped out by hand. Same when installing new main bearing. Slipped right in as soon as it was aligned properly.