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Hey all. Pulled the transmission on the engine on my way to splitting the cases. The HD manual references HD-35316A as the removal tool for the 5th gear. I did find a Jims tool for $300 conveniently available. Looking at the tool, I feel like I could make something comparable to get the job done, but probably not for repetitive use. Has anyone done this? Is there a lookalike on Uncle Jeffs that anyone has used? They seemed absent when I did a search.
George's Garage. I think I've seen this come up in my search results, but never gave it much attention. It's a new site for me and clearly something I need to become familiar with. $200 is still on the pricey side, but worth keeping in my back pocket.
I'm curious why you're pulling the 5th gear? Are you rebuilding the bottom end yourself? If your cranks are still good I think it is pretty cheap to have the bottom end done by a shop. I just looked into it and it was under $500 to rebuild the bottom end minus any crank work. That included replacing the 5th gear bearing and seal. At $200 for a tool I would just take it to a shop and have them pull it. I'd have them press out the crank too.
Last edited by OCSpringer; Oct 28, 2023 at 09:55 AM.
Yes, I am rebuilding the bottom end. I don't know what I have in the engine honestly. The bike sat in an open air garage for about 16 years without being ran. Taking apart the top end - the inside looked way better than expected. The whole engine needs a bath and a hard scrub down to get it looking anything like a motor that will turn over. So you can think of this as more of a passion project than anything that's going to become a daily rider.
I looked into what it would take to rebuild mine (2003) a couple weeks ago and found it was probably cheaper to send it out due to the tools involved. I talked with Dan at hammer performance and he gave me a lot of good advice on whether or not it really needed a rebuild and what my best course of action should be. I just finished a complete rebuild of my bike and it's definitely a labor of love.
Last edited by OCSpringer; Oct 28, 2023 at 05:53 PM.
I'm curious why you're pulling the 5th gear? Are you rebuilding the bottom end yourself? If your cranks are still good I think it is pretty cheap to have the bottom end done by a shop. I just looked into it and it was under $500 to rebuild the bottom end minus any crank work. That included replacing the 5th gear bearing and seal. At $200 for a tool I would just take it to a shop and have them pull it. I'd have them press out the crank too.
$500 seems like a great deal. Considering shop rates today.
Yeah. I got the bike cheap and I've never split the cases before, so it's gonna be a learning exercise and a good winter project. I'm hoping that it will only be a winter project and not a winter/spring/summer project
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5th gear removal on 93 XL1200
