Fifth gear replacement

[Mark222]

Well, after having the trans pulley nut back off and the splines wiped / reamded clean off the inside of the trans pulley I have to determine whether or not to replace the 5th gear in the trans.  Question #1, how do I know if it should be replaced?

Called Harley today and found out that the 5th for the '91 5 speed was a LCG (low contact gear) and they now only sell HCG (High contact gears).  And therefore a set is required - the 5th gear and the counter gear that rides on the shaft I presume?  Has a -94 part suffix, so they evidently changed and now only replace worn pieces  with the 94 and up pieces? Nice little gig at $325 for the set. 

I am thinking that replacing the 32T pulley with a 34T will help improve the gearing for this bike I am told that Andrews makes a steel pulley for $130  or so vs. HD's $197 price for the 32T.  Better product for less $$$?

So if I go with the Andrews pulley how will I know / how can I check to see if the 5th gear really needs to be replaced?

Mark

[bagga]

look at the splines on the 5th gear. if they a worn at all replace the gear. if you don't replace you will be replacing your drive pulley again next year. i went through this a few years ago. the parts scrub at the dealer told me i would be ok just replacing the pulley. he was wrong. if the splines are worn the pulley will never be completely tight on the 5th gear. trust me on this, if it look worn at all replace the gear.

[1997bagger]

Don't know if this interests you but if you have a gear problem, Ultima has the 6 speed installers kit for $499 and no shipping on Ebay. Would keep the lower gear ratio and the overdrive would equal the pulley change, just a thought.

[smittyon66]

I bought a new Ultima 6 speed for my 98 in late spring. Now I'm just hoping it makes it until the snow flies before I pull it back out.

Besides the drive pulley, Andrews also sells the gears you need. 5th main lists for about $160.

http://www.andrewsproducts.com/PDF_files/catalog/28_EV5SpdGear.pdf

[Dan89flstc]

You probably can find an entire gearset on ebay or even local shops, the going price has been somewhere around 150 bucks. There are a lot of gearsets around due to the 6 speed kits being installed.

[gryphon]

From what I've seen, the gearsets are going up in price. However, they are still a  bargain compared to buying single gears.

[Mark222]

I will be going with Andrews parts since HD is so proud of theirs.  I ordered the 5th gear assembly complete with the needle bearings installed and their steel 34 Tooth pulley for about $400.  Thought about the 6 speed sets but the low end within my budget for a 20 year old bike gave me pause based on quality history, so I went with the 34T pulley instead to obtain a 3:17 final, down from the 3:37.

So not I will just need to finish knocking out the gearset and press the old out, and new in.  Indie shop buddy has the tool I can use.  Whole event will be a bit less than $500 with all gaskets, seals etc.  Could be worse, and should be rolling again this weekend.  Parts should be in by Friday.

Thanks to all for the info and options / advice.

Mark

[Dan89flstc]

Don`t forget to replace the big ball bearing after you press the old 5th gear out of it. And be very careful when you push out that 5th gear, some cases have very thin webbing supporting the bearing on the inside, and the case can break. Use the tool, don`t hit the gear to drive it out.

[bagga]

Don`t forget to replace the big ball bearing after you press the old 5th gear out of it. And be very careful when you push out that 5th gear, some cases have very thin webbing supporting the bearing on the inside, and the case can break. Use the tool, don`t hit the gear to drive it out.

exactly. everything 89 said is absolutely right.

[tinkerman]

Just gotta say folks this is another one of those threads where the collective knowledge of the folks here at HTT contribute to a fellow being able to move forward on some mechanical repairs with a lot more confidence and info than winging it alone.

I have been on the receiving end here in situations similar to this and it is a huge benefit having access to the kind of info available here.

Kudo's to you all...OK, enough sucking up.....everyone back to work.....

tink