I am working on a friends 92 Electraglide that quit driving. I have pulled the primary off and found the splines stripped front the inside of the drive pulley. Around 1000 miles ago I replaced the oil seal and had the pulley off but noticed no play in the splines. Has anyone on here had a similar issue?

The owner was not rodding on the bike or doing a burn out at the time of failure.

 

Pretty common for around that year model...They make a kit that has pulley lock and nut...Usually the shaft is OK.

 

I've experience with pulley splines stripping, on my own machine as well as others. I've found a good practice that I use a Sharpie marker and mark everything I remove as to replace it back to its original orientation

 

ya that last post was all I had to offer (over zealous send button) Like I was writing b4, the orientation of the pulley to the 5th gear spline should be reinstalled exactly as it came off 4 the highest probability of a solid lasting fix. Since its already striped & your diving back in, and as much as I do not want to say this, I would recommend you tear all the way and replace the 5th gear as well. While your there I'd replace the shifter prawl lever assembly as well. I've found over the years examples of the inner 5th gear bearing "walking" over to the outer and causing unusual wear to the seal (your original issue) Regardless, the pulley stripped, replace the 5th gear as well and know you wont b going in a 3 rd time 4 free. The shift sprawl is a bonus, hope this is of some help 2 U and #ridesafe

 

Thanks!

Are there any special tools that I might run into a need for?

 

Volksrod this is definitely not a first time job IMO because of the amount of tear down. I experienced nearly the same issue with my machine & since I was working 4 a dealership (hchd) I had the benefit of several expert technicians looking over my shoulder. I initially replaced the output shaft seal and reassembled with original equipment ... it only lasted 1000 miles when the pulley stripped out. I went back in and just replaced the pulley because everything measured correct and "felt" right. That new pulley lasted again only 1000 miles. The third time in I tore all the way to the 5th gear which requires complete disassembly of the transmission again not really a first time job. I'm not saying you cannot accomplished this repair on your own but it would go a lot smoother with another set of experienced eyes, that may have already learned some lessons that you may not wish to learn on your friends machine. it's been a couple years but if i recall the only specialty tools you need is the bearing race puller & installation tool and deep snap ring pliers. Its been a few years so my memory is a little faded. i suggested you replace the shifter prawl lever assembly because it is easy 2 do at this tear down and uit has done its job 4 the last 18 years & has 2 be about done and due 4 a failure any time, probly make your hair stand up thinking about going is in for third time if you choose not 2 replace it and it fails within the next 18. I hope you find this a useful post, just writing from experience & what your wrenching on is a big job with plenty of room 4 error. Lastly, I do things over-the-top so if you really want 2 crush this thing I used a small ceramic block & and smoothed all the "contact or witness marks" on ALL the gears while i was in there. My Transmission shifted just fine before the repair but after it now shifts smoother & easier then any Harley I've ever ridden & I've ridden 100s & 100s. of em. DM me if u wish. Goodluck, enjoy N. Dakota & #ridesafe.

 

Use the revised kit and all will be well. your issue is very common for that year and model

 

if the splines on the main gear show any wear at all, replace the main gear. your problems will continue if you don't. i replaced 2 pulleys before i replaced the main gear. the second one lasted a couple of months. after the main gear was replaced i have about 10 years on this pulley.

 

Thanks for your input. I am definately not a new comer to this type of work and the project has been very smooth going. The only snag that I have run into is that I was either sold the wrong 5th gear or it has been updated and i need an updated gear to mate with it. I will check with the dealer tomorrow.