V-Twin Forum banner

1 - 17 of 17 Posts

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #1 (Edited)
It's time that I get started putting my 82 FXR back together. First thing that I need is rebuild parts for the transmission. Who makes quality (USA?) gaskets and seals? I know there are bearings not bushings like the old 4-speeds, but what are the common wear items, and where to get them, besides eBay part number searches? Is there a rebuild kit? Thanks, Joe
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #3
Thanks, I ordered the kit.
 

·
Registered
Joined
·
135 Posts
Hope this helps-
Trans parts are expensive.
AFAIK Andrews makes most of them. I needed a main drive gear, bearings, Main shaft, a few other parts .
Guess what? It all came within 200 bucks of a new Baker with O.D.!
So-for the same money I have a new treansmission.
Thoughts to think.......
 

·
Registered
Joined
·
911 Posts
Gearboxes are so durable it's common to buy complete later units (including five speed TC boxes) to swap the internals (then Ebay the case to get some of the already modest cash back) for less money then replacing a few parts in an old, higher mileage box. That's a fine way to accomplish the spline shaft upgrade and ditch the POS stock clutch. All the info is in this forum and was very helpful when I upgraded mine.
 

·
Registered
Joined
·
135 Posts
But.....the parts that go bad are the common ones and expensive.
The main shaft, trap door bearings, might as well do the main gear and bearing.
Throw in the N1 shifter ....yaaadaa yada...it gets real close to a brand new Baker slide-in kit
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #7
I'm going for originality, so I'm going to fix what needs fixing and rebuild this transmission. The Jim's kit includes all the bearings, as well as usual seals and gaskets, so I hope the hard parts are OK.
The previous owner brought the bike in two times for transmission leaks, and someone lost or broke one of the cover screws. I hope I don't find other problem repairs inside:

268374


The cover came off without drama, and it looks good so far:

268375


Following along in the shop manual, I removed the shift cam. The fork shaft looks bad but it is smooth and came out easily. I'll dress it before reinstalling.

268376


The shift forks don't look too bad, but I bought one NOS fork last year and spent the next hour or so looking for it! I have to spend a day or so to organize my stuff better, or I'll never get this done. Here's where I left off today:

268377


268378
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #8 (Edited)
The shift shaft needs replacement, as does the sprocket.

I found the new 1-2 shift fork and compared it to the old one. They have updated the design slightly:



The shop manual says compare the thickness of the pads to a new one. If they are worn more than .020", replace them. The new one measures .203" thick, so .183" is the limit. Mine measures .185" but I have a new one already. The 3-5 fork measures .186" and 4th measures .189". While they are technically ok, I'd like to find better or new ones. I see Mid-USA sells them for under $20, but I don't know if those are any good.

When I went to take off the sprocket, I found it loose on the spline! The tabs were bent on the nut but it wasn't tight at all. So I definitely need to replace the main drive gear. Sliding the gears to engage the dogs puts it in two gears at the same time and locks the shafts so I could remove the nut.



The right side cover came off without drama, but the clutch shaft wobbles. I haven't removed it to see what is worn. I hope it's easy to fix.



I'll be replacing the throw out bearing too. This one doesn't have the oil slinger?

 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #9
With the gears still locked together, I loosened the two big nylock nuts.



Then I tapped the main shaft and used the two slots machined in the trap door to remove it from the case.





Here's why the 5-speed is so much more modern than the old 4-speed. I could have done all this with the transmission in the bike. I actually did that on my Road King when the shift pawl spring broke.

 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #10
The shift pawl slides out of the case. I'll be disassembling it and replacing the springs, so I don't have to do this again.



I cleaned the case and gear cluster in my parts cleaner. Without oil, the Main Drive Gear bearing was very noisy, so that was shot too. I wonder if that has anything to do with loosening of the sprocket nut? There's a new one in the Jims kit.

Half the gears slide off their shafts from this end. They are held in by retaining clips, and new ones are in the Jims kit too.



Then by tapping the ends of the shafts, they slide out of their bearings. The counter shaft popped right out, but the main shaft needed more persuasive tapping.

Continuing the disassembly, I marked the gears so they go back in the same position as they were. This is important because they wear as a set, and reversing one of the pair will lead to premature wear.

 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #11 (Edited)
I inspected all the gears and shafts, and they seem to have worn evenly, no chipped teeth or scratches. Before I took it apart, I checked the gears for backlash, and could feel none. I should have used a dial indicator, but I forgot.

This is the only visible wear that I could find, the dogs in the countershaft 1st gear have been beat up. The mating gear dogs look fine.





The main shaft looks suspect, with this ding where the clutch hub mounts. The bearing surfaces look frosty, but I measured them anyway.



The shop manual doesn't give wear limits for the shaft bearing surfaces, so are these OK?

M/S inner primary bearing diameter .9826 - .9827"
M/S main drive gear bearing diameter 1.0003 - 1.0004"
C/S end bearing diameter .9837 - .9838"

Any comments on the condition of the shafts? Do they need replacement? I'm thinking I need a new main shaft.
 
  • Like
Reactions: Scotty_No1

·
Super Moderator
Joined
·
3,232 Posts
I would polish it some with scotch brite and see if the surface looks uniform afterwards. If there is much damage or wear it won't clean up easily. It's not always easy to see the depth of imperfecions based on images. By the way,thanks for the write up.
 

·
Registered
Joined
·
91 Posts
joe shovel FXR,
You should put your mainshaft and countershaft up in "centers" and check for "runout" somewhere in the center of the shaft.......I don't have the Shop-Manual here but it should list the limits of "runout" in the "Transmission-Section".

On your 5th-Gear-Mainshaft (the one in the case that the chain-sprocket attaches to)......you may want to rethink its ability to not leak oil/trans-fluid. In its current condition (caused by the loose sprocket hammering back-and-forth during gear-changes) will continue in the future.....even with new seals.
If you are bucks-down......take your time and apply a slight amount of silicone-seal to the splines before and after mounting the sprocket......then lock it down torqued to factory specs. Later the sprocket will still start to rock due to the pockets worn on the gear (in your photo)......and then very slight amount of trans-fluid will leak out and start to "wet" the sprocket.
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #14
I ordered a new Andrews 5th gear, so that's handled. As far as shift forks, I found a set of take-outs that are listed as part numbers 34191-79E, 34193-79E and 34195-79E for 90-98 FXR, 90-05 Dyna and Touring. My parts book lists the same part numbers but with B suffix. Usually that's just an improvement but not a change of fit or function. They are steel, not bronze like mine. Does anyone know what may be happening here? They look to be in good shape.
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #15
I fitted the clutch hub on the main shaft and it was loose. Further examination shows the taper is worn, so I ordered a NOS HD main shaft.

268495


The clutch release shaft is worn, and so is the finger. I found OEM ones on ebay, but the shaft doesn't have the grooves. Is that going to be OK? The length is the same.

268493


Unfortunately the case is also worn, you can see high spots where the grooves didn't wear the case. I suppose a sleeve is the only way to repair it. Live with it? Does anyone have a good replacement for me?

268494
 

·
Registered
Joined
·
91 Posts
Is it the Mainshaft tapper worn (?).........or is it the clutch-hub becoming "out-of-round", or a "burr" on the key-slot (?).
 

·
Registered
1982 FXR Shovelhead
Joined
·
94 Posts
Discussion Starter #17
Is it the Mainshaft tapper worn (?).........or is it the clutch-hub becoming "out-of-round", or a "burr" on the key-slot (?).
I'll know better when I get the new main shaft, but the hub will get a thorough lookover.

I also solved the mystery of the clutch shaft. In 1984 Harley redesigned the part to add a sleeve and oil seal to the case. They must have recognized the weakness of the first design. I have a -84 case coming, and will get the newer style shaft and finger.
 
1 - 17 of 17 Posts
Top