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My '89 FLHTC's shifter shaft lever finally gave up the ghost. After 32 years and two shift levers, the splines on the shaft was in very poor shape. The right fix was to pull the shifter pawl assembly and replace the whole thing. While I was in that deep, I thought I would upgrade my tranny pulley/sprocket (whichever you prefer) to the '94 and later setup. No issues with what I had, but it was a target of opportunity. A BIG THANKS to t150vej for his guidance as always.
I bought the Jims shifter pawl assembly and used mostly James gaskets. '94 and later pulley has a different size spacer/seal. The only special tool that I recommend having is the large pulley nut socket and IPB race puller/installer tool. It just makes life easier.
Here's a picture of the take off seals, o-rings, gaskets, etc... that was replaced. Not in picture, but I installed a new IPB race, primary chain, trapdoor gasket, and clutch cover gasket. Re-used tranny top cover gasket.
More ****.
My original pulley setup
Tranny was still in great shape after 100K miles. I marked the shifter forks. It's good practice.
OEM shifter pawl assembly splines have seen better days.
New pulley and shifter pawl assembly with new shifter lever. I put a grade 8 bolt with a high collar washer (learned that from t150vej) and put a decent torque on the lever. The old race is now part of my IPB tool, which is also a great tool to install the 5th gear seal. (bolt was mock up in pic)
All back together and no leaks. Total parts cost would probably be circa $300 (not counting tools), Labor was Free.
Last edited by daven9113; Oct 23, 2021 at 02:57 PM.
Nice job Daven,been adding tranny oil for a while now,gotta do mine over the winter too,It's such a pita.Mine's just the inner seal.Btw, like the gutted lowers.
Nice job Daven,been adding tranny oil for a while now,gotta do mine over the winter too,It's such a pita.Mine's just the inner seal.Btw, like the gutted lowers.
I agree. Adding a little tranny oil is just simpler. LOL. If you replace the IPB seal, use the double lip one (James). I just think it's easier to install than the single lip type that you can buy from the dealership.
nice , mines going under the knife next monday. i have a inner primary seal leak, one on the motor to primary
and one on the back of primary main shaft to clutch basket ..
only im not going it , i was going to tackle it , but some recent family ordeals need my attention.. so off to the shop she goes
i did get the seal kit.. james one...only i got a oem primary cover gasket also..and got the double lip shifter seal.. thats getting done while its apart also
i could live with it, but i figured get it done now while the shop has time... they specialize in older harleys
and i dont want it to get worse next season and be down . plus oil leaks aint good lol
Last edited by robwlf10; Oct 23, 2021 at 10:26 PM.
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Old Evo gets some love
Total parts cost would probably be circa $300 (not counting tools), Labor was Free.
