Harley Davidson Softail 1984-1999. Service manual — page 16

5-SPEED TRANSMISSION

The 5-speed Harley-Davidson transmission and shifter assembly is mounted in a separate housing and can be completely disassembled and serviced without having to disassemble the engine or remove the transmission housing. The 5-speed transmission is used on all 1986 and later Softail models.

The transmission service procedures in this chapter are arranged by sub-assembly—shifter assembly and transmission. Before servicing the transmission or shifter assembly, make sure the problem is not due to a faulty clutch adjustment or a problem with the primary drive system.

An external shift linkage assembly connects the gearshift lever to the transmission. The shift linkage assembly requires adjustment to compensate from normal wear to the linkage/shifter mechanism components or when the transmission housing was removed from the bike.

This chapter provides service procedures for the 5-speed transmission. Tables 1-3 are found at the end of the chapter.

PRODUCTION GEARS (1994 MODELS)

During the 1994 production year, two types of transmission gear sets were produced by Harley-Davidson—domestic ratios (U.S., Canada and Japan) and HDI ratios (Harley-Davidson International). Domestic ratio gears can be identified by a 0.03 in. (0.76 mm) radius groove machined in the center of each gear tooth. Motorcycles with HDI ratios are equipped with high contact ratio
(HCR) gears installed on the mainshaft and countershaft 2nd through 5th gears. HDI ratio gears do not have grooved gear teeth.

CAUTION Domestic and HDI ratio gears should not be intermixed. Running both types of gears in a single transmission assembly will damage mating gears.

SHIFT CAM ASSEMBLY

The shifter cam is mounted to the top of the transmission case, directly underneath the transmission top cover (Figure 1).

NOTE

Late 1991 and later models are equipped with a new style shifter cam (8, Figure 1) that does not require the use of the inner thrust washer (II, Figure 1). Early and late style shifter cams can be identified by the neutral indica tor actuator (Figure 2) mounted on the shifter cam. A cast neutral indicator actuator is used on early style shifter cams. Later style shifter cams use a pressed-in pin. In addition, on models with the late style shifter cam, 2 locating dowel pins are used to locate the left-hand support block (10, Figure 1) to the transmission case.

Removal

1. Disconnect the negative battery cable.