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gearbox rebuild tips

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Old Jun 10, 2010 | 05:45 AM
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shorty1's Avatar
shorty1
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Default gearbox rebuild tips

Hi
I have a 2004 sportster with 24,000 miles on the clock. I have had an issue with the gearbox "crunching" instead of the usual harley clunk. The dealer investigated and the clutch plates were burnt out so had them replaced. Unfortunatley this has not fixed the problem. The dealer was quite up front explaining the labour time involved in fixing the gearbox and how given the mileage that it may not be worth it.
This was my first bike and has great sentimental value so I'm not giving up on her. I'm going to have a go myself and have ordered the workshop manual and parts manual. The question is if any of you can give any sage words of advice before I start undoing things. I have little mechanical experience so keep it simple.
Thanks
Shorty
 
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Old Jun 10, 2010 | 09:45 AM
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HarleyScuba
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You have to take the engine apart and split the cases to get to the tranny. Keep everything really clean.
 
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Old Jun 10, 2010 | 10:42 AM
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shorty1
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Thanks HarleyScuba. Clean I can do, It's the spare bits left over at the end of the job that will be the problem (-:
 
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