Re: Sam Crow?

Old Crow wrote:
"Steve Irving" <sdirv@xxxxxxxxxxxxxxx> wrote in message news:48e8e8de$0$89398$815e3792@xxxxxxxxxxxxxxxxx
But I've regressed into childhood since I retired and became a non-working,
useless, non-productive member of society. It's either this kinda stuff or
politics, and I think we're all SICK of politics at this point...<sfsf>



OK, how about this. Sat I took the primary(both inner and outer)off my evo FLT to replace the shift lever on the trans. Found the lock screw had come out of the front final drive pulley, and the nut had backed all the way off and was floating on the shaft. The little lock screw was also floating around in the recesses of the pulley. Checked out the threads, cleaned and locktite'd them and torqued the sprocket nut back down. Locktited the lock screw, tightened it and buttoned the whole bike back up.
Took a little 20 mile ride with my wife on the back to get a nice hunk of prime rib for dinner and then back home for the night. Bike is much smoother now, actually shifts into the gears, and, I can find neutral.
Oh, and the prime rib was outstanding!


Any pre-94 EVO (that has not been updated) has this ailment. Surely get yourself a double and a seat cause I don't have good news.

If the pulley has been loose for an extended time it has eaten up the splines on 5th gear and will require it replacement as well. Take that early pulley and use it for a base for a hard luck trophy, buy a new pulley for 94 up you will find that it has a wider spline area to keep the pulley from working on the 5th gear splines (wrecking the splines and shearing the lock screw). Along with the new pulley is a shorter sleeve that is thicker to give the pulley a larger surface to bear against, a new seal is required for the larger diameter sleeve. Replace that quad seal that is between the sleeve and the bearing while you're in there. In addition to these fine updates the pulley is provided with a nut lock ring that is retained by 2 screws.

A second problem you may experience is that the shifter shaft has been eaten up by the loose shifter arm and the new shifter arm will soon come loose and fail much much faster than the original. When I do these I almost always replace the shaft at the same time as it is bad juju when a customer brings one back with the same complaint 6 to 9 mos later! This also provides a great opportunity to install a Posi-Shift to prevent those false neutrals you get when attempting a fast shift, thus killing two birds with one rock.

I hope it is a long time before you have to remove the primary again, since I did not do the work it will probably last your life time. On the other hand if it doesn't you are better prepared and can make a permanent fix.

Parts list for update
40250-94C pulley
40251-92A lock ring
33344-94 spacer (sleeve)
11165 quad seal
12067B mainshaft seal

Shifter shaft seal tip:
Install the seal after the shaft, wrap a square of plastic parts bag material around the shaft to let the seal slip over the parts of the shaft that will cut and ruin the new seal after the seal is past the snap ring grove in the shaft you can pull out the plastic.

Inner Mainshaft seal tip: (this is the little thin seal that goes in the tip of the 5th gear shaft with the mainshaft going through it)
With a rotary sander or fine stone grinder wheel, very carefully very lightly break the edge of the seal outer band to allow it to engage in the 5th gear bore without hanging up and causing the seal to be destroyed when attempting to press in. Same as the shifter seal, cut a larger square of parts plastic bag material to cover the nasty parts of the mainshaft so they don't cut the seal when you install it (later models have splines that will devastate a new seal).

Clutch hub mounting:
Tapered shaft clutch hubs on the second generation clutch (1st generation used the 4 speed style clutch). These hubs have a very thin area between the key slot and the outer surface and split very easily. When the hub splits it will roll over the key and junk the mainshaft!

DO NOT OVERTIGHTEN the clutch hub nut!!!!

An aftermarket part is made to reinforce the hub, a ring that presses on the tip of the hub that protrudes through the basket bearing on the back side. This ring comes in 2 sizes, so get the right one for your hub. Seems last time I looked I had to go back to an 03 Custom Chrome book to find the rings. Not certain they are still available.

Before final installation of the hub, lap the hub onto the mainshaft for a perfect fit. This is critical to get the most grip on the mainshaft without over tightening the retaining nut. The grip on the shaft is made by the taper engagement not the tightness of the nut or the key. Over tightening the nut will cause the hub to split. (burnouts and wheelies may split the hub too)(don't ask)

Jim's makes a replacement mainshaft the has the later style splines on it so you can use the later (3rd generation) clutch and eliminate this problem. But that is another story....

5th gear replacement tips:
There is a huge risk when removing 5th gear from the trans. The gear is pressed into the output bearing from the right side. The output bearing is installed from the left side. So to get 5th gear out you have to push it out of the bearing, but the bearing is held in the case by a very thin lip on the right side. As you push against 5th gear to remove it from the bearing you are essentially pushing against the previously described lip. This lip is so thin that it is not uncommon for it to get blown off the case when removing 5th gear if it is stuck in the bearing. Due to the diameter of 5th gear there is no way to back up the case when making this press. Scott at Bay Area Performance has built a tool that will grab the output bearing from the left side and push 5th gear out of the bearing without stressing the case, ship the case to him (a UPS bill is cheaper than a new case).

Seems the rain has affected me already, it's going to be a long wet season.....
Surely have yourself a refreshing beverage on my tab if you made it this far, and archive this in your manual for future reference.


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