shifter shaft after forward controls
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Tourer
Joined: Apr 2005
Posts: 352
Likes: 0
From: denver via chicago
shifter shaft after forward controls
gents,
removed my primary cover because i let the chain drop when adjusting the slack. decided this would be a good time to put on the forward controls since i removed a foot peg anyway. the questions is, what about the old shifter shaft? have anyone you removed this thing. can it be done withought removing the primary housing? i was thinking i could just cut it with my dremmel, and try to wiggly it out the back, theres a little room. but it might not work and then i don't know what i'd do, guess take the whole primary off. anyway, just curious what all of you did? im kind of in the middle of this so any help on the topic would be greatly appreciated. can't ride today cause its raining pretty good but i was hoping to have it back on the street monday.
thanks a lot
db
removed my primary cover because i let the chain drop when adjusting the slack. decided this would be a good time to put on the forward controls since i removed a foot peg anyway. the questions is, what about the old shifter shaft? have anyone you removed this thing. can it be done withought removing the primary housing? i was thinking i could just cut it with my dremmel, and try to wiggly it out the back, theres a little room. but it might not work and then i don't know what i'd do, guess take the whole primary off. anyway, just curious what all of you did? im kind of in the middle of this so any help on the topic would be greatly appreciated. can't ride today cause its raining pretty good but i was hoping to have it back on the street monday.
thanks a lot
db
Tourer
Joined: May 2006
Posts: 319
Likes: 0
From: Cape Coral, FL
RE: shifter shaft after forward controls
You will need to remove inner primary to get out, then plug hole back side of inner primary, easier options are, chrome cap that fits over end of shaft or cut shaft off just past chain inspection cover, and get a new inspection cover that does not have hole in it.
RE: shifter shaft after forward controls
I left my old shaft in. I slid it over until it was flush w/ the outter cover and then wedged it behind a bolt head coming out of the crank case. This is not the proper way but it works, I have 2600 miles on my bike with no shifting problems.
flush w/ outter cover
old shaft wedged behind bolt head
Good Luck
flush w/ outter cover
old shaft wedged behind bolt head
Good Luck
Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
RE: shifter shaft after forward controls
You can remove the original shift shaft lever without removing the primary. Use a hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins. Tape a wrench on one end to get a better grip (on the end of the blade so as you pull on the wrench you will be on the cutting stroke of the blade). Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom. I cut about three quarters thru then wrapped a rag around the shift lever and used vise grips on the other end of the shaft splines and sheared it off. Here's a photo of mine with the 2005 kit and a 2006 shift rod on my 2006 Low Rider.
Updated info below:
Updated info below:
Originally Posted by WS6 formula
You don't have to remove the primary on the 2006 and up Dyna's
The 2006 and up kit instructions says you have to remove the primary to install a longer rear transmission shift lever and to remove the original shifter shaft that goes through the primary cover. Both can be done without removing the primary.
I installed the 2005 and earlier kit (P/N 49080-03A) with a longer 2006 custom polished stainless steel shift rod (P/N 33815-06) that comes with the stronger heim joints (they won't break like the original joints). You have to use a longer shift rod with the 2005 kit other wise the front shift lever will hit the primary when you up shift. The custom shift rods are a lot nicer then the cadmium plated shift rod in the kit and the original that came with the bike.
Removing the original shift shaft lever
Get a hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins. Tape a wrench on one end to get a better grip (on the end of the blade so as you pull on the wrench you will be on the cutting stroke of the blade). Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom. Position the shaft so you can cut about a quarter inch from the lever (not in the welded area). Use your other hand to guide the top of the blade as you cut. After cutting through, the shaft will slide right out, and the lever will just fall to the floor.
Cover for the original shift shaft lever hole
I used a chrome carriage bolt http://www.chromebolt.com/51618-x-134-chrome-carriage-bolt-p-845.html, and put a two inch piece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole. If you have a black primary: Paint a unplated carriage bolt. Aluminum cover: Scotch brite a chrome carriage bolt.
Installing the new rear trans shift lever
https://www.hdforums.com/forum/dyna-glide-models/220845-did-the-oem-forward-controls-last-week.html
(Don't do it, leave in the original) Using the original rear transmission shift arm has two benefits, appearance and performance. The shift rod will sit at a more level angle, and you will also have a shorter shift throw.
(You may have to change the rear transmission shift lever only if your using the 2006 and up kit and have a hard time finding neutral. This is caused by a longer front shift lever on the 2006 and up kits which in turn will take less movement of your foot to change gears or go into neutral.)
Forward control part numbers here:
http://www.harley-davidson.com/gma/gma_product.jsp?PRODUCT%3C%3Eprd_id=84552444229229 3&FOLDER%3C%3Efolder_id=2534374302288287&ASSORTMEN T%3C%3East_id=2534374302288287&bmUID=1224980167820 &bmLocale=en_US
Shift linkage part numbers here:
http://www.harley-davidson.com/browse/browse_products.jsp?FOLDER%3C%3Efolder_id=25343743 02291395&bmUID=1224980000342&bmLocale=en_US
Check prices here:
http://www.chicagoharley.com/shop/
http://www.lshd1.com/servlet/StoreFront
https://www.zanottimotor.com/shopping/partLookUp.html
Larger image here:
http://img56.imageshack.us/img56/2760/afterapril2020081020x63bz2.jpg
Larger image here:
http://img56.imageshack.us/img56/4373/saturdaymarch292008059kp3.jpg
You don't have to remove the primary on the 2006 and up Dyna's
The 2006 and up kit instructions says you have to remove the primary to install a longer rear transmission shift lever and to remove the original shifter shaft that goes through the primary cover. Both can be done without removing the primary.
I installed the 2005 and earlier kit (P/N 49080-03A) with a longer 2006 custom polished stainless steel shift rod (P/N 33815-06) that comes with the stronger heim joints (they won't break like the original joints). You have to use a longer shift rod with the 2005 kit other wise the front shift lever will hit the primary when you up shift. The custom shift rods are a lot nicer then the cadmium plated shift rod in the kit and the original that came with the bike.
Removing the original shift shaft lever
Get a hacksaw blade and tape each end with duct tape, leaving about two inches exposed in the middle. Also put some duct tape on the primary and cylinder cooling fins. Tape a wrench on one end to get a better grip (on the end of the blade so as you pull on the wrench you will be on the cutting stroke of the blade). Slip the blade between the primary and engine from the bottom of the bike with the wrench end on the bottom. Position the shaft so you can cut about a quarter inch from the lever (not in the welded area). Use your other hand to guide the top of the blade as you cut. After cutting through, the shaft will slide right out, and the lever will just fall to the floor.
Cover for the original shift shaft lever hole
I used a chrome carriage bolt http://www.chromebolt.com/51618-x-134-chrome-carriage-bolt-p-845.html, and put a two inch piece of rubber hose on the threads then added some shrink sleeving on the hose to get a nice snug press fit into the empty shaft hole. If you have a black primary: Paint a unplated carriage bolt. Aluminum cover: Scotch brite a chrome carriage bolt.
Installing the new rear trans shift lever
https://www.hdforums.com/forum/dyna-glide-models/220845-did-the-oem-forward-controls-last-week.html
(Don't do it, leave in the original) Using the original rear transmission shift arm has two benefits, appearance and performance. The shift rod will sit at a more level angle, and you will also have a shorter shift throw.
(You may have to change the rear transmission shift lever only if your using the 2006 and up kit and have a hard time finding neutral. This is caused by a longer front shift lever on the 2006 and up kits which in turn will take less movement of your foot to change gears or go into neutral.)
Forward control part numbers here:
http://www.harley-davidson.com/gma/gma_product.jsp?PRODUCT%3C%3Eprd_id=84552444229229 3&FOLDER%3C%3Efolder_id=2534374302288287&ASSORTMEN T%3C%3East_id=2534374302288287&bmUID=1224980167820 &bmLocale=en_US
Shift linkage part numbers here:
http://www.harley-davidson.com/browse/browse_products.jsp?FOLDER%3C%3Efolder_id=25343743 02291395&bmUID=1224980000342&bmLocale=en_US
Check prices here:
http://www.chicagoharley.com/shop/
http://www.lshd1.com/servlet/StoreFront
https://www.zanottimotor.com/shopping/partLookUp.html
Larger image here:
http://img56.imageshack.us/img56/2760/afterapril2020081020x63bz2.jpg
Larger image here:
http://img56.imageshack.us/img56/4373/saturdaymarch292008059kp3.jpg
Last edited by WS6 Formula; Apr 5, 2010 at 07:58 PM.
Tourer
Joined: Sep 2006
Posts: 324
Likes: 6
From: Melbourne, Florida
RE: shifter shaft after forward controls
[sm=exactly.gif]that's what I did with mine,very easy to do and looks great. Why anybody would pay the dealer to install forwardsI will never know.[sm=biker.gif]
Tourer
Joined: Dec 2006
Posts: 344
Likes: 0
From: Finland
RE: shifter shaft after forward controls
Let me get this straight for me (maybe others too) Sorry being so ignorant. If you use the hacksaw to cut the shaft outside the inner primary does the shaft come totally out from the outer primary side?
If it does, what about the holes left behind? Is there any factory solutions or do I have to use a cork from a wine bottle?
If I’m doing forwards to my 07 Dyna Custom what kind of kit I have to use? 05? Whats the difference between 05 kit and 07 kit?
I’d like to avoid that situation where I eventually have to go to the stealer with lots of parts and beg them to do it again for money ;-)
Novice
Joined: Aug 2006
Posts: 16
Likes: 0
From:
RE: shifter shaft after forward controls
htc,
Those are good questions. I wondered the same thing because there is no way the shaft is going out the inner primary side unless you take the inner apart, and that's the whole point of cutting the shaft in the first place, to avoid having to remove outer and inner primary covers. I also wondered about how to plug the hole left behind in the inner primary. I got the 06 kit from Harley and installed myself, and like, HOGRIDA_06, I left the shaft in the primary and wedged it behind the same bolt head that he did. In fact the shaft kinda blends into the stock primary cover which is cool because the 06 kit comes with a plug for the hole left behind in the outer cover which is chrome and will probably stand out like a sore thumb, but it didnot come with anything to plug the hole in the inner.I'll post some pics so you can see, looks the same as HOGRIDA_06's only mine isn't black.
Tim
[IMG]local://upfiles/16328/7C93FC35A2C44CE6B5CA64A9F8CED533.jpg[/IMG]
[IMG]local://upfiles/16328/61BA0681F542455B9CEDA57ACD986655.jpg[/IMG]
[IMG]local://upfiles/16328/FC2FC8C9537C400DA231E3B73BEA9A42.jpg[/IMG]
Those are good questions. I wondered the same thing because there is no way the shaft is going out the inner primary side unless you take the inner apart, and that's the whole point of cutting the shaft in the first place, to avoid having to remove outer and inner primary covers. I also wondered about how to plug the hole left behind in the inner primary. I got the 06 kit from Harley and installed myself, and like, HOGRIDA_06, I left the shaft in the primary and wedged it behind the same bolt head that he did. In fact the shaft kinda blends into the stock primary cover which is cool because the 06 kit comes with a plug for the hole left behind in the outer cover which is chrome and will probably stand out like a sore thumb, but it didnot come with anything to plug the hole in the inner.I'll post some pics so you can see, looks the same as HOGRIDA_06's only mine isn't black.
Tim
[IMG]local://upfiles/16328/7C93FC35A2C44CE6B5CA64A9F8CED533.jpg[/IMG]
[IMG]local://upfiles/16328/61BA0681F542455B9CEDA57ACD986655.jpg[/IMG]
[IMG]local://upfiles/16328/FC2FC8C9537C400DA231E3B73BEA9A42.jpg[/IMG]
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Stellar HDF Member
Joined: Mar 2006
Posts: 3,124
Likes: 255
From: From Long Island, now in So. Cal
RE: shifter shaft after forward controls
You can leave it open because that thru hole is sealed, no oil will leak out with or without the shaft. I stuck a stainless carriage bolt in mine: http://www.mmsacc-stainless.com/html/carriage_bolts.htm
The 06 and up comes with a rear shift lever that you have to remove the primary to install, and also comes with a longer shift rod, (I'm not sure but the front lever may also be taller). You can use the 06 and up kit with out changing the rear shift lever. The 05 kit works as long as you use a 06 shift rod, other wise the front shift lever will hit the primary when you up shift.
Last edited by WS6 Formula; Feb 7, 2010 at 04:55 AM.
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Tourer
Joined: Sep 2006
Posts: 324
Likes: 6
From: Melbourne, Florida
RE: shifter shaft after forward controls
Get the 06-07 forwards, once you cut the shaft it will pull out no problem. The new forwards come with a chrome cap to cover the hole and also comes with a longer shift rod you will not need it, will shift fine without it. It took me about an hour to do the whole job, no problems at all.
ORIGINAL: htc
Let me get this straight for me (maybe others too) Sorry being so ignorant. If you use the hacksaw to cut the shaft outside the inner primary does the shaft come totally out from the outer primary side?
If it does, what about the holes left behind? Is there any factory solutions or do I have to use a cork from a wine bottle?
If I’m doing forwards to my 07 Dyna Custom what kind of kit I have to use? 05? Whats the difference between 05 kit and 07 kit?
I’d like to avoid that situation where I eventually have to go to the stealer with lots of parts and beg them to do it again for money ;-)
Let me get this straight for me (maybe others too) Sorry being so ignorant. If you use the hacksaw to cut the shaft outside the inner primary does the shaft come totally out from the outer primary side?
If it does, what about the holes left behind? Is there any factory solutions or do I have to use a cork from a wine bottle?
If I’m doing forwards to my 07 Dyna Custom what kind of kit I have to use? 05? Whats the difference between 05 kit and 07 kit?
I’d like to avoid that situation where I eventually have to go to the stealer with lots of parts and beg them to do it again for money ;-)
Tourer
Joined: Dec 2006
Posts: 344
Likes: 0
From: Finland
RE: shifter shaft after forward controls
Gentlemen’s, I would like to thank you for valuable information. Here in Finland it’s not enough that the parts cost three times more, the labour also (only HD labour). Also the USD exchange rate just now makes me a bit happier from EURO point of view when ordering the parts from States. With UPS and customs the result will be under half what it costs here.