Harley transmission side cover removal install#
Remember to install the new o-ring into the hole first. Connect the new cable to the clutch lever, and feed the other end into the hole on the front of the transmission.By unscrewing a screw on the clutch assembly inside the transmission, you should be able to remove the assembly and then the clutch cable. You should be able to remove the cable housing completely now.Note that there will be an o-ring sealing this junction that you should replace. Unscrew the cable housing from the front of the transmission.Unbolt the clips securing the clutch cable housing to the motorcycle.Remove the side transmission cover by unscrewing two screws.Remove the drainplug for the transmission (it is a few inches away from the primary chain adjustment screw) and drain the oil from the tranny.Allocate another 30-45 minutes for this job. You will likely need a flashlight and socket extensions for this. It is obvious which bolts/nuts hold the exhaust on. Remove the exhaust: Remove the nuts at the exhaust flange at the engine, and then undo four or so screws/nuts near the bottom of the exhaust.Allocate 20-30 minutes of your time for this. Remove the three hard-to-access nuts with the “wiggler”.This will give you more room to remove those hard-to-access nuts for the left foot peg. Remove the seat and, optionally, the battery.I use Mobil 1 10W-40 Racing synthetic oil and Bosch 3311 filter, available from Autozone for $10/qt. Optional: As you are going to have the bike apart you might as well change the oil and filter.1 quart 20W-50 for replacing the oil in the transmission.Cable: Bikers Choice TR-060332 available from Amazon for $37.You will also need some sort of oil drain pan to catch the oil you will need to drain from the transmission.īelow are the basic parts needed for replacing the clutch cable: Even with this tool to attach to a ratchet, the loosening the nuts for the footpeg is difficult. You will also need a “wiggler” (e.g., Harbor Freight #67986) to help you remove the left footpeg. So again I’d suggest investing in a motorcycle jack (I use Harbor Freight #65620 which costs $35), borrowing one or else having a motorcycle shop do this job for you. Otherwise, it will be hard to refill the transmission with one quart of oil without it spilling out of the transmission fill hole. If you plan on replacing the transmission oil (might as well since you will be going through quite a bit of work to remove the transmission cover), it is mandatory to jack up the rear of the bike. It may be possible to do it without it, but I haven’t thought it through and thus it is beyond the scope of this article to do the job without it. By writing this article, I hope to help other Buell Blast owners faced with this task avoid these three issues.įirst off, I highly recommend having a motorcycle jack to do this job. Part of the long delay was due to 1) procrastination on fixing the bike due to slight intimidation of never having done it before, 2) time it would take to research and order the correct parts, and 3) breaking the replacement clutch cable due to overzealous assembly. The Audi would get the transportation duties for the next few months.
While I was thankful that this happened in the garage before I even started the bike, this meant a ride on the Buell would have to wait another day. I then grabbed a fistful of the clutch lever and-crap! The clutch cable snapped at its end at the lever. Having an excuse in hand-it was fetching groceries or going to an appointment I don’t remember which-I donned my motorcycle jacket, helmet, gloves, and hopped on the Buell. Remove the allocation and clean the case.ģ) See more in the Harley Fork Shaft Hole Removal chapter.It was a beautiful November day, perfect for motorcycling. See that in the Harley Fork Shaft Hole Removal chapter and follow these steps:ġ) With the case empty now is the time to remove the fork shaft hole on the right side of the case.Ģ) Tape trap door flat holes, except for the top three, speed sensor and mounting screw bores, transmission top cover, shifter drum support screw bores, transmission drain hole bore, main drive gear bearing bore, countershaft needle bearing bore, fork shaft bore, shifter shaft bore before you remove fork shaft hole. If you are installing a JIMS Fat 5, it is best to remove the Fork Shaft Hole at this time.
Follow along with Bob and these steps to make sure the job is done correctly.Ī very important note. Once done you can install the main drive gear bearing. Use a new bearing and follow these steps. This video shows Harley countershaft bearing installation. Articles on Harley-Davidson How-to and More
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