digging into the tranny

[adam79]

the gears

Ok, from the way Im holding it, which way do these gears this spin? Clockwise or ccw? I thought I'd be able to tell from the wear, but I cant, and I dont want to grind the wrong side.

[adam79]

just got the picture up

[DGXSER]

Adam, both sides mesh eventually, one on acceleration, one on deceleration or engine braking. So you should really do both sides of all four gears.

As to rotation, I believe the countershaft rotates clockwise when viewed from the right side of the engine when the bike is upside right or the clutch side of the engine. So the gear with the dogs (fourth gear) will rotate the same direction as it meshes with the splines on the shaft. 1st gear rides on the bearing so it will be engaged on the left side as you look at the gear from the side that faces fourth when accelerating if I am picturing this all correctly. Or as you are holding the gears, fourth gear will turn counterclockwise on acceleration engaging against first gear. Clear as mud?? Just do both sides.

[bikerphil]

The countershaft spins the same direction as the rear wheel spins when the bike is moving forward. From the left side of the bike, the crankshaft spins clockwise which spins the primary shaft clockwise via a chain. This primary shaft has gears which mesh with the countershaft gears spinning them in an opposite direction, counterclockwise. Focus mostly on the grinding of the forward direction dogs and slots, but the backside (downshifting) dogs and slots should not be overlooked.

[TopCatGr58]

Hey Adam,

If you'll go back and look at the tech tip, the way you are holding the 1st gear, go around the slots CCW, and the edge you first contact going in that direction is the forward contact. You can then put the 4th gear against it and figure out which side of the dog makes contact with that side of the slot.

The text for the grinding diagrams doesn't show up well due to the auto-resizing the site does, but clicking on the image will POP up another view of it, and then you will have the ability to click again to zoom, and then the text will be very legible!
T.C.

[adam79]

I finished the back cut on the 1st gear dogs and the shelves they contact with. The angle on the dogs is steeper than the shelves, but all dogs make contact with all shelves in every position. But, the original trapezoid shape of the dogs is a bit more squarish now. Although the angles of the dogs are a bit steeper than the shelves, the general idea of the slant has been achieved.

Here's the (general) angle of the dogs:


and their new shape:



It is hard to see with my cell phone cam, but the back cut on the shelves turned out more like recessed pockets:

[trbig]

I don't know how aggressive you ride, but there are times on hard and fast deceleration that the gears jump in and out just like they do on the acceleration side. You might consider doing both sides as mentioned before.

Just a suggestion though.


Tod

[adam79]

filter washer

I was missing my oil filter washer, so I ordered one, and it seems very thin for the purpose (as described to me) that it is used for. Is this the right washer?

[DGXSER]

Adam,

I have not had my oil filter off yet so I do not know. Sorry.

[wingnut]

Yep that's a filter washer.

[adam79]

the countershaft

Everything is going great, and I am about to put the countershaft back into the bike. I've gotten a little ahead of myself though, and I cant remember if there was a washer in between the end of the countershaft and the countershaft bolt.

[bikerphil]

I cant remember if there was a washer in between the end of the countershaft and the countershaft bolt.

No. The washer is attached to the bolt as in the picture you posted.

[adam79]

thats what i thought, thanks

[adam79]

I just got the countershaft and fork shaft back in....Wow, that was...lets just say it took some patience, cussing, distraught, sweating, and then more patience. I had to slide the middle and 1st gears to the end of the shaft, let them get slightly into place, then once I did that and got the countershaft down of course the middle drive was kinked and didnt want to slide back on, so after 8 more tries I get it, and then of course the shift fork falls into the engine--- Im sure you guys know the score. now it's just a matter of reassembly and torquing.

I noticed old blue threadlock on all of the pan/cover bolts, so I'll put new threadlock on when I put them back in, but are there any other bolts that need it? One more thing, I called Napa for the gasket material, and the type they recommended was cork-rubber, which of course they were out of. For the people that make their own gaskets, is that what you used? If not, what type did you use?

[TopCatGr58]

Hey Adam,

The only place that I found threadlock was on the 3 torx bolts that secure the countershaft bearing plate. A PO might have applied it, or it might have been worked on by a HARLEY Mechanic! They locktite everything!

The paper stuff I used was the green colored paper, the dark/black colored was a little thinner, possibly more compressed, didn't remember what the lable said regarding use, ie., higher temp locations, or water vs. oil application. Using with Yamabond should ensure no leaking with either. IMHO, cork is too flimsy!

Congrats on wrestling the countershaft/gears/shift forks and such back into place. NOW before you button up the bottom tranny pan, spin the rear wheel, put the shift lever back on and do a dry run thru the gears to make sure they will shift properly and go into position and not bind, etc.

IF you put the 5th gear on backwards, it won't work!
T.C.

PS, that washer has a small ridge/lip and needs to be sure that it's centered well when putting it back on the countershaft and the bearing, before torquing. You don't want that coming loose!