Harley Davidson Touring Models 84-98 FLH, FLHT, FXR. Service manual - page 20

CHAPTER SEVEN

FIVE-SPEED TRANSMISSION

The five-speed 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.

Tables 1-4 are at the end of the chapter.

SPECIAL TOOLS

The five-speed transmission requires a number of special tools. These tools and the part numbers are listed with the individual procedures. For a complete list of the special tools mentioned in this manual, refer to Table 12 in Chapter One. The tools used in this chapter are either Harley-Davidson or JIMS special tools. JIMS special tools are available through many aftermarket motorcycle suppliers.

When purchasing special tools, make sure to specify that the tools required are for the FXR, FLH and FLT series models from 1984-1999. Many of the tools are specific to this transmission. Tools for other transmissions and years might be slightly different.

PRODUCTION GEARS (1994-1998 FLH AND FLT MODELS)

From 1994-1998, there are two different five-speed transmission assemblies with different gear configurations depending on in which country the motorcycle is sold.

The majority of the motorcycles are equipped with the standard High Contact Ratio (HCR) transmission. The gears do not have a radius groove.

The other transmission has unique gears with a 0.03 in. (0.76 mm) radius groove machined in the center of each gear tooth on the second through fifth gears on both main and countershafts.

The two different transmissions are identified by the model year serial number located on the right side of the transmission case behind the shifter or top cover. The first prefix 9 digit indicates the transmission type. The HRC transmission is identified with a double 99 in the serial number, similar to No. 995172001, and the other transmission is identified with a single 9, similar to No. 95172001.

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