Harley Davidson Softail Delux FLSTN BIKE 2011-2015. Service Manual — page 39
1
2
3
4
5
6
sm03455
1. Bearing inner race
2. Extension shaft
3. Wrench flat
4. Installer sleeve
5. Washers
6. Nut
Figure 5-23. Installing Bearing Race
INSTALLATION
TORQUE VALUE
FASTENER
35.3-38.0 Nm
26-28 ft-lbs
Primary chaincase housing
sealing fasteners
NOTES
•
Cover mainshaft clutch hub splines with tape to prevent
the splines from damaging the inner primary cover oil seal.
•
See
. In next step, be sure dowels (1) in
crankcase gasket (2) engage holes in crankcase.
1.
See
. Place crankcase gasket in place on
gasket surface (2). Be sure dowels in gasket engage dowel
holes (3).
2.
Spread a thin film of oil on mainshaft oil seal lip and rubber
portion of crankcase gasket. Be careful not to damage
mainshaft seal when installing chaincase over the primary
bearing inner race on the mainshaft.
3.
See
. Insert
new
sealing fasteners.
4.
See
. Tighten fasteners in sequence shown to
26-28 ft-lbs (35.3-38.0 Nm).
5.
Install the primary chain, clutch, and compensating
sprocket as an assembly. See
.
6.
Install chain tensioner assembly.
7.
Install starter. See
.
NOTE
Replace the gasket between the primary chaincase cover and
chaincase each time the cover is removed.
8.
Install primary chaincase cover. Fill with lubricant. See
5.3 PRIMARY CHAINCASE COVER, Installation
9.
Adjust drive belt tension.
10. Connect negative battery cable.
2
1
1
sm02381
1. Dowel
2. Crankcase gasket
Figure 5-24. Crankcase Gasket
2
1
3
3
sm02382
1. Crankcase
2. Gasket surface
3. Dowel holes
Figure 5-25. Crankcase
2013 Softail Service: Drive 5-11
sm02383
Figure 5-26. Primary Chaincase Sealing Fastener
3
2
5
1
4
sm02384
Figure 5-27. Primary Chaincase Sealing Fastener Torque
Sequence
5-12 2013 Softail Service: Drive
5.6
CLUTCH
REMOVAL AND INSTALLATION
To remove the clutch without disassembly or for installation
instructions, see
CLUTCH PACK ONLY
TORQUE VALUE
FASTENER
7.9-11.3 Nm
70-100
in-lbs
Clutch diaphragm spring
retainer bolts
Partial Disassembly
This procedure can be performed on the motorcycle without
removing the clutch shell or hub.
1.
Remove primary chaincase cover. See
2.
See
. Remove six bolts (1) (metric) to release
diaphragm spring retainer (2) from clutch hub. Loosen
each bolt gradually and in a star sequence around the
hub.
3.
Remove diaphragm spring retainer, diaphragm spring (3)
and pressure plate (4) from clutch hub.
4.
Remove friction plates (5, 7), steel plates (6), damper
spring (8) and damper spring seat (9) from clutch hub (11).
Cleaning And Inspection
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
1.
Wash all parts in cleaning solvent, except for friction plates
and bearing, if removed. Dry parts with low pressure
compressed air.
2.
Check
friction plates
:
a.
Use compressed air to remove all lubricant from the
friction plates. Do not wipe off with a rag.
b.
Measure the thickness of each plate with a dial caliper
or micrometer.
c.
If the thickness of any plate is less than 0.143 in. (3.62
mm), discard all friction plates and replace with an
entirely
new
set.
d.
Look for worn or damaged fiber surface material (both
sides).
NOTE
Replace all nine friction plates with an entirely new set if any
individual plate shows evidence of wear or damage.
3.
Check the
steel plates
:
a.
Discard any plate that is grooved or bluish in color.
Blue plates are likely warped or distorted.
b.
Check each plate for distortion. Lay the plate on a
precision flat surface. Insert a feeler gauge between
the plate and the flat surface in several places.
Replace any steel plate that is warped more than
0.006 in. (0.15 mm).
4.
Hold the clutch hub and rotate the clutch shell to check
bearing for smooth operation. Replace the bearing if it
runs rough, binds or has any end play.
5.
Inspect the primary chain sprocket and the starter ring
gear on the clutch shell. Replace the clutch shell if either
are badly worn or damaged.
6.
Check the slots that mate with the clutch plates on both
the clutch shell and hub. Replace if slots are worn or
damaged.
NOTE
Springs are identified by a dab of paint on one face. See the
parts catalog to verify the correct spring is installed.
7.
Check the diaphragm spring and diaphragm spring retainer
for cracks or bent tabs. Replace part if either condition
exists.
2013 Softail Service: Drive 5-13
2
3
1
10
4
12
9
8
7
6
5
15
11
13
14
sm02704b
9.
1.
Damper spring seat
Bolt (6) (metric)
2.
10.
Diaphragm spring retainer
Mainshaft nut (metric)
11.
3.
Clutch hub
Diaphragm spring
4.
12.
Pressure plate
Clutch shell
13.
5.
Bearing
Friction plate (9)
6.
14.
Steel plate (8)
Retaining ring
15.
7.
Retaining ring
Narrow friction plate
8. Damper spring
Figure 5-28. Clutch Shell Assembly
Assembly
NOTE
Submerge and soak all friction plates in primary chaincase
lubricant for at least five minutes.
1.
See
. Install the narrow friction plate on the
clutch hub.
2.
See
. Install damper spring seat (9) on clutch
hub (11). It must sit inboard of narrow friction plate (7).
NOTE
See
. Notice damper spring (4) orientation with
respect to damper spring seat (3).
5-14 2013 Softail Service: Drive
3.
See
. Install damper spring (8) on clutch hub
with the concave side facing away from damper spring
seat.
4.
Install a steel plate (6) with round edge outward and then
a friction plate (5) on the clutch hub. Install seven
remaining sets in the same manner, alternating between
steel plates and friction plates.
5.
Install pressure plate (4) on clutch hub aligning holes in
plate with threaded bosses on hub.
6.
Seat diaphragm spring (3) in recess of pressure plate with
the concave side inward.
7.
Align holes in diaphragm spring retainer (2) with threaded
bosses on clutch hub. Tabs on spring retainer contact flats
on inboard side of bosses.
8.
Install six bolts (1) (metric) to secure diaphragm spring
retainer to clutch hub. Alternately tighten to 70-100
in-lbs
(7.9-11.3 Nm).
NOTE
Always install a new gasket between primary chaincase cover
and chaincase. Failure to replace this gasket may cause
primary chaincase leaks.
9.
Install primary chaincase cover. Fill primary chaincase
with lubricant. See
1
2
sm02417
1. Narrow plate
2. Regular plate
Figure 5-29. Friction Plates
CLUTCH PACK AND BEARING
Complete Disassembly
1.
Remove the primary chaincase cover. See
2.
Remove clutch assembly. See
3.
Follow
all
partial
disassembly
information
under
NOTE
Do not disassemble the clutch shell and hub assembly unless
the bearing, hub or shell require replacement. Replace the
bearing if disassembled.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
4.
See
. Remove retaining ring.
5.
See
. Support clutch shell in arbor press with
ring gear side up. Use a suitable press plug to press hub
from bearing in clutch shell.
6.
See
. Remove retaining ring from groove in
clutch shell bore.
7.
See
. Support clutch shell in arbor press with
ring gear side is down. Use a suitable press plug to remove
bearing.
8.
Clean and inspect components. See
.
sm02419
Figure 5-30. Clutch Hub Retaining Ring
sm02421
Figure 5-31. Pressing Clutch Hub From Bearing
2013 Softail Service: Drive 5-15
Assembly
1.
Place clutch shell in arbor press with ring gear side up.
Support clutch shell bore on sprocket side to avoid damage
to ears on clutch basket.
2.
Using a suitable press plug, press against outer race until
bearing contacts shoulder in clutch shell bore.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
3.
See
. Install retaining ring with flat side toward
bearing.
4.
Place clutch shell in arbor press with sprocket side up.
Center hub in bearing. Support bearing inner race with a
sleeve on transmission side.
5.
Press hub into bearing until shoulder contacts bearing
inner race.
6.
See
. Turn assembly over. Install retaining ring
in groove of clutch hub.
7.
Assemble clutch components. See
8.
Install clutch. See
5.4 DRIVE COMPONENTS, Installation
NOTE
Always install a new gasket between primary chaincase cover
and chaincase. Failure to replace this gasket may cause
primary chaincase leaks.
9.
Install primary chaincase cover. Fill primary chaincase
with lubricant. See
sm02422
Figure 5-32. Install Clutch Shell Retaining Ring with Flat
Side Against Bearing
sm02424
Figure 5-33. Pressing Bearing From Clutch Shell
5
2
7
6
1
3
4
sm02426
1. Steel plate
2. Clutch hub
3. Damper spring seat
4. Damper spring
5. Starter ring gear
6. Primary chain sprocket
7. Narrow friction plate
Figure 5-34. Clutch Stackup
5-16 2013 Softail Service: Drive
5
4
3
2
1
sm02427
1. Diaphragm spring
2. Jamnut
3. Adjuster screw
4. Retaining ring
5. Bolt (6) (metric)
Figure 5-35. Assembled Clutch
2013 Softail Service: Drive 5-17
5.7
TRANSMISSION SPROCKET
REMOVAL
TOOL NAME
PART NUMBER
FINAL DRIVE SPROCKET LOCKING
TOOL
HD-46282-A
MAINSHAFT LOCKNUT WRENCH
HD-47910
PILOT
HD-94660-2
1.
Remove primary chaincase. See
2.
Remove debris deflector. See
NOTE
Loosen both axle adjusters an equal number of turns to main-
tain wheel alignment.
3.
See
. Remove e-clip (1). Loosen rear axle nut
(2). Loosen both axle adjusters (3) to release tension on
the drive belt.
NOTE
Only remove sprocket nut while transmission is installed in
frame. Failure to do so will result in damage to transmission
and/or transmission stand.
4.
Remove transmission sprocket.
a.
See
. Remove both screws (1) and lock-
plate (2).
b.
See
. Secure sprocket using FINAL DRIVE
SPROCKET LOCKING TOOL (Part No. HD-46282-
A) (3). Final drive sprocket locking tool must rest
against lower portion of rear fork pivot nut (2).
NOTE
Sprocket nut has a right-hand thread.
c.
Install PILOT (Part No. HD-94660-2) on mainshaft.
d.
Remove the sprocket nut using MAINSHAFT
LOCKNUT WRENCH (Part No. HD-47910) (1).
5.
Remove belt from sprocket as sprocket is removed.
1
2
3
sm02594a
1. E-Clip
2. Axle nut
3. Axle adjuster
Figure 5-36. Axle Adjusters
4
5
3
2
1
sm02428
1. Screw (2)
2. Lockplate
3. Sprocket nut
4. Sprocket
5. Main drive gear
Figure 5-37. Transmission Sprocket
5-18 2013 Softail Service: Drive
2
1
4
3
sm02430
1. Mainshaft locknut wrench
2. Rear fork pivot nut
3. Final drive sprocket locking tool
4. 3/4 in. breaker bar
Figure 5-38. Sprocket Nut Removal (Typical)
CLEANING AND INSPECTION
1.
Using a non-volatile cleaning solvent, clean sprocket of
all grease and dirt.
2.
Inspect belt and sprocket. See
3.
Inspect both main drive gear and mainshaft seals. Replace
if damaged.
INSTALLATION
TOOL NAME
PART NUMBER
FINAL DRIVE SPROCKET LOCKING
TOOL
HD-46282A
MAINSHAFT LOCKNUT WRENCH
HD-47910
PILOT
HD-94660-2
TORQUE ANGLE GAUGE
SNAP-ON TA360
TORQUE VALUE
FASTENER
135.6 Nm
100 ft-lbs
Transmission sprocket nut,
initial torque
47.5 Nm
35 ft-lbs
Transmission sprocket nut,
final torque
10.2-13.6 Nm
90-120
in-lbs
Transmission lockplate screws
NOTE
Install sprocket nut only while transmission is installed in frame.
Failure to do so will result in damage to transmission and/or
transmission stand.
1.
Place transmission sprocket in position. Install the belt on
the sprocket as the sprocket is installed.
2.
If reusing the sprocket nut, apply LOCTITE 271 HIGH
STRENGTH THREADLOCKER (red) to the threads of the
sprocket nut.
NOTES
•
Never get oil on the threads of the sprocket nut or the
integrity of the lock patch may be compromised.
•
The transmission sprocket nut has right-hand threads.
Turn the nut clockwise to install.
3.
See
. Apply a thin film of clean engine oil to
the mating surfaces of the sprocket nut (3) and the
sprocket (4). Install the sprocket nut until finger-tight.
4.
See
. Lock transmission sprocket with the
FINAL DRIVE SPROCKET LOCKING TOOL (Part No. HD-
46282A) (2). The locking tool must rest against the rear
fork pivot (3).
5.
Install PILOT (Part No. HD-94660-2) on mainshaft.
6.
Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
47910), tighten sprocket nut to 100 ft-lbs (135.6 Nm) initial
torque.
7.
Loosen sprocket nut one full turn.
8.
Tighten to 35 ft-lbs (47.5 Nm ).
NOTE
See
. To determine proper angles during final
tightening, scribe lines (3) or use TORQUE ANGLE GAUGE
(Part No. SNAP-ON TA360) after the 35 ft-lbs (47.5 Nm) torque
is applied.
9.
Continue turning sprocket nut an additional 35-40 degrees.
NOTE
The lockplate has four screw holes and can be turned to either
side. This should provide screw hole alignment without having
to additionally tighten the nut. If the screw holes cannot be
properly aligned, tighten the nut slightly until the holes align.
Do not exceed 45 degrees. Never LOOSEN nut to align the
screw holes.
10. Install lockplate over transmission sprocket nut with two
of lockplate's holes aligned with sprocket's two tapped
holes.
NOTES
•
New screws have LOCTITE patches.
•
Screws can be re-used up to three times if LOCTITE 271
HIGH STRENGTH THREADLOCKER (red) is applied
before installation.
•
To confirm the lockplate security, install BOTH screws.
11. See
. Install two screws (1) to secure lockplate
(2) to sprocket (4). Tighten to 90-120
in-lbs
(10.2-13.6
Nm).
12. Install primary chain assembly. See
NOTE
Never reuse gasket between primary chaincase cover and
chaincase after cover removal. Failure to replace this gasket
may cause primary chaincase leaks.
13. Install primary chaincase cover. Fill with lubricant. See
14. Verify pivot shaft torque. See
2013 Softail Service: Drive 5-19
15. Adjust belt tension. See
16. Verify vehicle alignment and tighten rear axle. See
17. Install debris deflector. See
2
1
4
3
sm02435
1. Mainshaft locknut wrench
2. Final drive sprocket locking tool
3. Rear fork pivot nut
4. 1/2 in. breaker bar
Figure 5-39. Sprocket Nut Installation (Typical)
1
2
3
45
o
sm02439
1. Sprocket nut
2. Transmission sprocket
3. Line scribed
Figure 5-40. Sprocket Nut Final Tightening
5-20 2013 Softail Service: Drive
5.8
DRIVE BELT
REMOVAL
1.
Remove rear wheel. See
.
2.
Remove primary chain, clutch, engine compensating
sprocket, and chain adjuster as an assembly. See
3.
Remove primary chaincase housing. See
4.
Place a support under rear fork and engine. Remove pivot
shaft and spacer. See
.
5.
See
. Slip drive belt (2) from transmission
sprocket (1).
1
2
3
sm02584
1. Transmission sprocket
2. Belt
3. Rear wheel sprocket
Figure 5-41. Belt and Transmission Sprocket
INSPECTION
See
1.12 DRIVE BELT AND SPROCKETS, Inspection
.
INSTALLATION
Never bend belt forward into a loop smaller than the drive
sprocket diameter. Never bend belt into a reverse loop.
Over bending can damage belt resulting in premature
failure, which could cause loss of control and death or
serious injury. (00339a)
NOTE
FXST and FLSTF/B models use a 20 mm wide belt.
1.
See
. Install belt (2) over transmission sprocket
(1).
2.
Install pivot shaft and spacer. Remove support holding
engine and rear fork. See
.
3.
Install the primary chaincase housing. See
.
NOTE
The gasket between the primary chaincase cover and chain-
case must be replaced each time the cover is removed. Failure
to replace this gasket may cause primary chaincase leaks.
4.
Install primary chain assembly. See
5.
Install primary chaincase cover. Fill with lubricant. See
6.
Install rear wheel. See
7.
Align vehicle. See
8.
Adjust belt tension. See
2013 Softail Service: Drive 5-21
SUBJECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE NO.
TRANSMISSION
6.1
FASTENER TORQUE VALUES
FASTENER TORQUE VALUES IN THIS
CHAPTER
The table below lists torque values for all fasteners presented
in this chapter.
NOTES
TORQUE VALUE
FASTENER
6.5 CLUTCH RELEASE COVER, Assembly and
Installation
10.2-13.6 Nm
90-120
in-lbs
Clutch cable fitting
6.5 CLUTCH RELEASE COVER, Assembly and
Installation
14.9-17.6 Nm
132-156
in-lbs
Clutch release cover screws
6.6 TRANSMISSION ASSEMBLY, Assembly
115.3-128.8 Nm
85-95 ft-lbs
Mainshaft/countershaft nuts
6.6 TRANSMISSION ASSEMBLY, Assembly
13.6-17.0 Nm
120-150
in-lbs
Shift drum detent arm fastener
6.6 TRANSMISSION ASSEMBLY, Assembly
6.4-7.1 Nm
57-63
in-lbs
Shift drum lock plate fasteners
6.8 TRANSMISSION CASE, Assembly
24.4-31.2 Nm
18-23 ft-lbs
Shifter pawl centering screw
6.4 SHIFTER, Shift Lever Replacement
10.9-16.3 Nm
96-144
in-lbs
Shifter peg
6.4 SHIFTER, Shifter Rod Adjustment
9.0-13.6 Nm
80-120
in-lbs
Shifter rod jam nut
6.8 TRANSMISSION CASE, Assembly
24.4-29.8 Nm
18-22 ft-lbs
Shifter rod lever pinch screw, transmis-
sion lever
6.4 SHIFTER, Shifter Rod Adjustment
7.9-10.2 Nm
70-90
in-lbs
Shifter rod to lever locknut
6.4 SHIFTER, Shift Lever Replacement
17.6-21.7 Nm
13-16 ft-lbs
Shift lever pinch bolt: FXS
6.4 SHIFTER, Shift Lever Replacement
24.4-29.9 Nm
18-22 ft-lbs
Shift lever pinch bolts: all but FXS
6.6 TRANSMISSION ASSEMBLY, Installation
31.2-33.9 Nm
23-25 ft-lbs
Transmission bearing housing screw
6.6 TRANSMISSION ASSEMBLY, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
6.8 TRANSMISSION CASE, Installation
19.0-28.5 Nm
14-21 ft-lbs
Transmission drain plug
6.8 TRANSMISSION CASE, Installation
20.3 Nm
15 ft-lbs
Transmission mounting bolts, 1st torque
6.8 TRANSMISSION CASE, Installation
46.1-52.9 Nm
34-39 ft-lbs
Transmission mounting bolts, final torque
6.6 TRANSMISSION ASSEMBLY, Installation
10.2-13.6 Nm
90-120
in-lbs
Transmission top cover
2013 Softail Service: Transmission 6-1
6.2
SPECIFICATIONS: TRANSMISSION
SPECIFICATIONS
Table 6-1. Transmission Specifications
DATA
TRANSMISSION
6-speed forward constant
mesh
Type
Part No. 99851-05 (qt)
FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE
LUBRICANT
Part No. 99824-03/00QT (qt)
SYN3 20W50 Oil
32 oz. (946.4 ml)
Capacity (dry)
Table 6-2. Transmission Gear Ratios
GEAR RATIO
GEAR
3.34
First (low)
2.31
Second
1.72
Third
1.39
Fourth
1.19
Fifth
1.00
Sixth (high)
NOTE
Final gear ratios indicate the number of mainshaft revolutions
required to drive the output sprocket one revolution.
SERVICE WEAR LIMITS
Table 6-3. Main Drive Gear Specifications
MM
IN
MAIN DRIVE GEAR (6th)
0.0076-0.043
0.0003-0.0017
Bearing fit in transmission
case (loose)
0.025-0.076
0.001-0.003
Fit in bearing (press-fit)
none
none
End play
Table 6-4. Mainshaft Tolerance Specifications
MM
IN.
MAINSHAFT TOLERANCE
0.00-0.08
0.000-0.003
Mainshaft runout
none
none
Mainshaft end play
0.05-0.66
0.002-0.026
5th gear end play (axial)
0.009-0.052
0.0004-0.0020
5th gear clearance (radial)
0.023-0.056
0.0009-0.0022
Main drive gear (6th) fit
Table 6-5. Countershaft Tolerance Specifications
MM
IN
COUNTERSHAFT
TOLERANCE
0.00-0.08
0.000-0.003
Countershaft runout
0.025-0.08
0.001-0.003
Countershaft end play
0.03-0.58
0.001-0.023
1st gear end play (axial)
0.010-0.052
0.0004-0.0020
1st gear clearance (radial)
0.03-1.02
0.001-0.40
2nd gear end play (axial)
0.010-0.052
0.0004-0.0020
2nd gear clearance
(radial)
0.03-1.07
0.001-0.042
3rd gear end play (axial)
0.010-0.052
0.0004-0.0020
3rd gear clearance
(radial)
0.03-0.71
0.001-0.028
4th gear end play (axial)
0.010-0.052
0.0004-0.0020
4th gear clearance
(radial)
Table 6-6. Shifter Dog Clearance Specifications
MM
IN
SHIFTER DOG
0.33-3.07
0.013-0.121
1st
0.41-3.51
0.016-0.138
2nd
0.25-3.17
0.010-0.125
3rd
0.46-3.28
0.018-0.129
4th
0.18-2.97
0.007-0.117
5th
0.56-3.33
0.022-0.131
6th
Table 6-7. Bearing Housing Bearing Specifications
MM
IN
BEARING HOUSING
BEARING
0.0025-0.0356
0.0001-0.0014
Fit in bearing housing (tight)
-0.010
-0.0004
Fit on countershaft (tight)
+0.030
+0.0012
Fit on countershaft (loose)
-0.010
-0.0004
Fit on mainshaft (tight)
+0.030
+0.0012
Fit on mainshaft (loose)
6-2 2013 Softail Service: Transmission
Table 6-8. Shifter Fork Specifications
MM
IN
SHIFTER FORKS
0.102-0.305
0.004-0.012
Shifter fork to cam groove end
play
0.102-0.4060
0.004-0.016
Shifter fork to dog ring end
play
6.55
0.258
First and second gear shift
fork pad thickness wear limit
5.03
0.198
Third and fourth gear shift fork
pad thickness wear limit
6.55
0.258
Fifth and sixth gear shift fork
pad thickness wear limit
2013 Softail Service: Transmission 6-3
6.3
TRANSMISSION
POWER FLOW
See
. The 6-speed transmission consists of two
parallel shafts supporting six gears each. The longer, or
mainshaft (7), also supports the clutch and serves as the input
shaft. The shorter shaft is called the countershaft (8).
Each gear on the mainshaft is in constant mesh with a corres-
ponding gear on the countershaft. Each of these six pairs of
gears makes up a different speed in the transmission.
The transmission gears are divided into two types, gears that
rotate with the shaft, and gears that spin freely on the shaft. A
gear that rotates with the shaft always meshes with a free-
wheeling gear. Also, three dog rings are able to slide sideways
on the shaft. These dog rings are used to change transmission
speeds. The dogs on the sides of dog rings engage dogs on
adjacent freewheeling gears, transmitting power through the
transmission.
Gear shifting is accomplished by three forks which fit into
grooves machined into the dog rings that slide on the guide
hubs. The position of the shifter forks is controlled by a drum-
shaped shifter cam located in the transmission bearing housing.
Neutral
Power is introduced to the transmission through the clutch. In
neutral, with the clutch engaged, the mainshaft 1st, 2nd, 3rd
and 4th gears are rotating. No power is transferred to the
countershaft since countershaft 1st, 2nd, 3rd and 4th gears
are freewheeling gears.
First Gear
When the transmission is shifted into first gear, the dog ring
between countershaft 1st and 2nd, which rotates with the
countershaft, engages countershaft 1st, which has been spin-
ning freely on the countershaft driven by mainshaft 1st.
Now countershaft 1st is no longer freewheeling, but locked to
the countershaft causing the countershaft and countershaft
6th to turn. Countershaft 6th transmits the power to the main
drive gear and the sprocket as shown (1).
Second Gear
Second gear is engaged when the dog ring between counter-
shaft 1st and 2nd is shifted out of countershaft 1st and engages
countershaft 2nd. This locks countershaft 2nd to the counter-
shaft to complete the power flow as shown (2).
Third Gear
Two shifter forks are used to make the shift from second to
third. One fork moves the dog ring between countershaft 1st
and 2nd to its neutral position. At the same time another fork
engages the dog ring between countershaft 3rd and 4th with
countershaft 3rd. This locks countershaft 3rd to the countershaft
to complete the power flow as shown (3).
Fourth Gear
Fourth gear is engaged when the dog ring between counter-
shaft 3rd and 4th is shifted out of countershaft 3rd and engages
countershaft 4th. This locks countershaft 4th to the countershaft
to complete the power flow as shown (4).
Fifth Gear
Two shifter forks are used to make the shift from fourth to fifth.
One fork moves the dog ring between countershaft 3rd and
4th to its neutral position. At the same time another fork
engages the dog ring between mainshaft 5th and 6th with
mainshaft 5th. This locks mainshaft 5th to the mainshaft to
complete the power flow as shown (5).
Sixth Gear
The shift from fifth to sixth gear occurs when the dog ring
between mainshaft 5th and 6th is shifted out of mainshaft 5th.
It is shifted directly into the main drive gear (6th gear). The
main drive gear is locked to the mainshaft. this results in a
direct one-to-one drive ratio from the clutch to the sprocket as
shown (6).
6-4 2013 Softail Service: Transmission
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