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Old 04-10-2008, 06:07 PM
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The Transmission Rebuild

I recently purchased a '96 Road King transmission for an FXR I am building. Since the trans was an Ebay purchase, and going into basically a new build...I want to go thru it with a total rebuild. New gaskets, seals, and bearings. I am getting the cases powdercoated also so that it looks new again. I need to bore the swingarm pivot shaft hole larger to accept the updated '07 larger diameter pivot shaft and spherical bearings now used in Harley's FL series rubbermount bikes, instead of the old 5/8 shaft and swingarm cleveblocks....a much better system.

Hopefully this will explain a few procedures, and show just how simple the transmissions are. Basically all this would apply to 5 or 6 speeds, and right side drive or left. They are all assembled in the same manner with basically the same components. Normally this would be done in the bike, with the trans case still bolted in...but because I want this to look new, and bore the shaft out...I will be doing this on a bench. None of the basic rebuild actually requires pulling the transmission. This should also serve as a guide to anyone wanting to pull their 5 speed, and install a 6, as the techniques/tools will always be the same.

#1 shows the basic Harley FLT transmission.

#2 shows the JIMS tool for pulling the inner primary race used with wet primaries.

#3 here the tool is slipped over the race, and the race is pulled from the mainshaft.

#4 here I am simply removing the transmission top, leaving the neutral indicator sensor installed.

#5 shows the trans top opened up, and I am removing the electronic speedo sensor.

#6 shows the view from the topside, most transmission problems can be diagnosed thru the top.



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Transmission Rebuild Part 1: The Disassembly
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Old 05-05-2008, 09:53 PM
One mile from home.
Awesome job Brad! Read the entire thing and only fell asleep once.

I'm curious about the powder process, they looked to have bead blasted everything?

Clean work bro!
Old 05-08-2008, 07:03 AM
CC Member/Contributor
yes Markee, i use Powder and Performance Coatings out of Richmond, Va. everything is media blasted.
Old 05-13-2008, 10:44 PM
CC Member/Contributor
Great thread, very informative! Thanks for sharing.

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