Transmission Issue
Thread Starter
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
So It's been a minute. Summer is here and life if getting in the way. Time is always a precious commodity. Did get a nice ride in yesterday.
Thx to the long holiday weekend and a vac day last Friday, I was able to put a good day into this today.
Things went pretty well. I got the bearings replaced in the new '04 trap door, and installed the '04 gear set. '04 shifter forks and drum assy are also now in. All new gaskets installed and buttoned it up with top cover. Still have to do the side cover install. Noticed tho that the ramp assy that connects to the clutch cable is dif between the '91 & '04. The one that came with the '04 has 21 degrees stamped on it and the '91 has 18 degrees stamped. What's the dif and which should I use?
Another concern is that the edges of the '04 trap door do not line up exactly with the housing of the '91 trans case. Should I have used the trap door from the '91? Thinking it's fine and just a cosmetic thing. Everything seems to function properly thus far.
Thx to the long holiday weekend and a vac day last Friday, I was able to put a good day into this today.
Things went pretty well. I got the bearings replaced in the new '04 trap door, and installed the '04 gear set. '04 shifter forks and drum assy are also now in. All new gaskets installed and buttoned it up with top cover. Still have to do the side cover install. Noticed tho that the ramp assy that connects to the clutch cable is dif between the '91 & '04. The one that came with the '04 has 21 degrees stamped on it and the '91 has 18 degrees stamped. What's the dif and which should I use?
Another concern is that the edges of the '04 trap door do not line up exactly with the housing of the '91 trans case. Should I have used the trap door from the '91? Thinking it's fine and just a cosmetic thing. Everything seems to function properly thus far.
Seasoned HDF Member
Joined: May 2017
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From: NorCal
The more degree the easier the pull. Therefore, 21⁰ is a "easy pull". But that being said, it also has to move a bit further in order to complete lift. Some have trouble, some don't. Depends on the clutch setup.
Thread Starter
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
Thx. Clutch setup will stay stock for now. See what the final adjustment brings me. Think I will try the '04 (21 degree), the current clutch pull always did feel somewhat heavy.
Seasoned HDF Member
Joined: May 2017
Posts: 5,915
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From: NorCal
Lots to factor. The diaphragm spring is often thought "the heavier the better" but unless it's slipping with high hp it's overkill. Especially on your hand and forearm!
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Road Captain
Joined: Jul 2014
Posts: 721
Likes: 18
From: Galesville, WI
And thoughts on the '04 trap door on a '91 case?
Seasoned HDF Member
Joined: May 2017
Posts: 5,915
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From: NorCal
I can't say for sure as I've never done it. On my '93 I have the stock ramp with the Burley EasyPull and that made it a one finger pull. On my '04 I did use the 21⁰ ramp with the stock clutch and that was about a 30% reduction in effort. As for the trap door, I really don't know if it will work. Maybe one of the Transmission experts will chime in.
Seasoned HDF Member
Joined: May 2008
Posts: 21,031
Likes: 12,555
From: South Carolina
I have a 1999 touring trap door on my 1989 softail transmission case, other than having to drill and tap it for the softail type drain plug it was plug and play.
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Seasoned HDF Member
Joined: May 2017
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From: NorCal
Atta Boy Dan! I was actually thinking of you when I said Transmission Experts. LOL! Didn't you also use larger diameter ball bearings in the ramp assy?
Seasoned HDF Member
Joined: May 2008
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From: South Carolina
The larger ball bearings are in the trap door, `99 and later used the larger ball bearings, the inside diameter of the bearings remained the same.