Does your XL jump out of 4th gear?

Classic short-frame models

Does your XL jump out of 4th gear?

Postby hennesse » Sun Sep 19, 2021 2:43 am

This fix was submitted by Rick Simpson (the decal guy)

THIS FIX WILL KEEP ANY XL FROM JUMPING OUT OF GEAR. I USED TO WORK AT A HARLEY DEALER WHO DID A LOT OF DIRT TRACK BIKES AND THIS WORKS VERY WELL. AND WE PROBABLY DID THIS TO MORE THAN 500 XL & XR TRANSMISSIONS.
GOING BY THE PARTS BOOK:

TAKE OUT THE TRANSMISSION

ON THE MAIN SHAFT REMOVE THE #28 RETAINING SNAP RING - #34 MAIN SHAFT 3RD GEAR WASHER - AND #27 M/S 3RD GEAR.
ON THE #34 MAIN SHAFT 3RD GEAR WASHER TAKE A DIE GRINDER AND GRIND OFF THE " EARS" ON THE INSIDE OF THE WASHER SO THAT IT IS COMPLETELY ROUND ON THE INSIDE.
NEXT PLACE THE REWORKED #34 MAIN SHAFT 3RD GEAR WASHER BACK ON THE MAIN SHAFT 1ST. - THEN #27 M/S 3RD GEAR - THE PUT ON THE #28 RETAINING SNAP RING.

SO IT WILL BE
#34 MAIN SHAFT 3RD GEAR WASHER(REWORKED)
#27 M/S 3RD GEAR
#28 RETAINING SNAP RING

NOW YOU WILL HAVE TO GET 2 NEW SHIFT FORKS ( I PREFER THE OEM BRASS FORKS)
1 EACH - +.020 LONGER FORK #34292-72
AND
1 EACH - -.020 SHORTER FORK #34293-72

IF I REMEMBER CORRECTLY THE -.020 IS USED ON THE MAIN SHAFT 3RD GEAR & THE + .020 FORK IS USED ON THE COUNTER SHAFT
IT MAY BE THE OPPOSITE AS ITS BEEN A WHILE SINCE I HAVE DONE A TRANS.

THEN YOU ASSEMBLE THE TRANSMISSION PER THE SERVICE MANUAL JUST MAKE SURE YOU CAN SHIFT THROUGH ALL THE GEARS AND THE SLIDER GEARS AND THEY DON'T HIT EACH OTHER. THEY WILL BE VERY CLOSE. THE #27 M/S 3RD GEAR WILL RIDE ON THE SNAP RING WITH NO PROBLEM. AND THE GEAR WILL GO INTO 4TH GEAR DEEPER AND NOT JUMP OUT OF GEAR. TRY TO SET THE END PLAY ON BOTH SHAFTS SOME WHERE IN THE MIDDLE OF THE TOLERANCE AND NOT TOO TIGHT.
IF YOU HAVE ANY QUESTIONS EMAIL ME. [email protected]
RICK
Attachments
simpson-1.jpg
From the parts book
simpson-1.jpg (76.06 KiB) Viewed 1351 times
simpson-2.jpg
Rick's fix
simpson-2.jpg (43.57 KiB) Viewed 1351 times
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hennesse
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