The bike is a 2007 Screaming Eagle Road King CVO. FLHRES3.
It started with occasional grinding then an oil leak from the primary. I pull the primary apart. The oil leak is from the inner primary bearing seal. The inner primary bearing and race look ok. The primary chain made witness marks on the inner cover. The inner clutch hub bearing feels ruff, so I found the grind(s). Then I find the internal spline on the clutch hub has sheared splines. Close inspection shows the inner clutch hub bearing is pressed together cocked ever so slightly. That explains the damaged spline. The friction material looks fairly new. I have no idea and no way of finding out prior maintenance, repairs, or modifications. The new clutch plates and cocked hub indicate that someone was in there and didn't do it right. So far I've bought a complete clutch assembly, an updated compensator and tensioner, bearings, and a seal and gasket kit, all from HD. I also bought all the pullers and drivers to replace the fore mentioned parts. I'm in over $2k but I don't mind because when I'm finished I will have a reliable primary and clutch. So far so good right?
To start the re assembly I pull the main seal off, something I should have done during the during the disassembly. I wasn't sure if the main bearing felt ruff. With the seal off I can see galling of the ball bearing. Now I have to pull the transmission apart.
Some questions;
Has any one the JIMS Transmission bearing and seal kit? I read in a review that mentions JIMS makes the kit for HD. $500 for the JIMS kit vs. $700 for the HD kit. I'm not looking to save money, I want a lasting quality product.
Next up is the additional tools I need to do the the trans. I didn't mind springing $500-$600 for specialty tools to do the primary but now we'er going over the top. Has anyone bought the trans tools for a one off repair like this and wants to sell them? I've tried 'net searches and cam up dry. I'd also appreciate any tips or advice on procedure(s) or sourcing quality parts. Thanks everyone!

 

I used the Jims kit when I rebuilt my transmission when my MDB went out, it included just about EVERYTHING. As for tools, I used most from Georges Garage. On assembly I ugraded to Jim's trapdoor plate that uses the older/wider trapdoor bearings and included new shafts for the shifting forks.

Harley has a few superceded parts now:
35122-06A OUTPUT GEAR ASY,DRIVEN
35467-06C MAINSHAFT, XMSN, INPUT SHAFT

 

I was going to go with the Jims rebuild kit, $500. Then I found out that HD sells the complete transmission gear and shift assembly including the main drive gear and bearing, P/N 35246-10B $874. I thought for the extra $374 the HD kit was a better value. The issue I'm having now is finding the tools needed to remove and install the main drive gear bearing. Both Jims tool #900 and Georges tool #620200 are out of stock from the respective manufactures. Monday I will be calling around to the various retailers to see if someone has either one in stock. I already have several hundred dollars into primary drive tools. Depending on which MDB tool I can find I'll be close to $1K in specialty tools. I wish there was a tool rental company to help keep expenses down. I'm a retired auto mechanic with over 47 years in the field with who knows how many tens of thousands of dollars I have into tools and shop equipment so I'm used to spending on tools but this is getting a little pricy. I guess I'm a Harley mechanic now.
Any how I really appreciate every bodies responses, help and advice. If anyone has any additional info please post it. I will keep you-all posted of my progress and the outcome. Thanks again.

 

While the splines dyeing may be partly due to pressing in clutch bearing being wonky, the production 6 speeds are are known for the clutch splines stripping out. I suspect is simply poor fit from the factory on some hubs.. The primary chain moved more outboard on the later primaries also..

Not sure what the output gear changes were but the main shaft change was partly due to HD adding a step to the mainshaft to stop inner primary bearing walk.. You will need to use the latest TC primary bearing if the shaft is changed.

 

BTW, Don't know if it's an issue with later Jim's kits but their 5 speed kits had some gear spacers were thinner than the original HD spacers on the kit I bought for the 5 speed. . I used the original HD spacers.