Harley-Davidson Big Twin 4 speed Transmission Rebuild With Frank Kaisler
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- Опубликовано: 15 окт 2024
- This Video is brought to you by Lowbrow Customs www.lowbrowcus...
Like a shop manual in video form! Follow along and learn all of the skills you need to get miles and miles of trouble free shifting out of your Harley-Davidson Big Twin Four Speed transmission / gearbox. In this installment of the Lowbrow Customs instructional video series for chopper nerds and restoration enthusiasts alike, Big Twin guru Frank Kaisler uses his 40 years plus experience to guide the viewer through a complete teardown and rebuild of a typical Harley-Davidson four speed transmission. Frank has rebuilt countless transmissions and the novice or experienced rebuilder can follow along with this video. Frank also shows the proper method to reinstall the transmission into the frame with proper shimming and alignment.
Video Covers:
Disassembly
Inspection
Shifter Fork Alignment
Reassembly
Installation
Own your own copy of the DVD: www.lowbrowcus...
00:11 - Intro
01:11 - Removing the transmission from Frame
05:48 - better view of what the mounts look like on the motorcycle.
06:41 - Transmission Top Disassembly.
06:50 - Remove Speedo drive cable.
07:28 - Remove the Clutch Arm.
08:05 - Remove the Transmission bottom plate.
09:27 - having a 4 speed Transmission work stand helps wonders - www.lowbrowcus...
10:40 - Taking the top off.
16:29 - How to check to see how close your shifter forks are to center while in neutral.
18:05 - How to check and measure the countershaft cluster's end play.
19:25 - Removal of the Shifter Shaft and Shifter forks prep.
22:12 - Kicker side Cover Removal.
24:06 - What your Throw out bearing looks like and how it works.
24:37 - How your kicker gear works.
25:34 - Mystery item, check bottom troth of the side cover for metal flakes.
26:29 - Back to removing the shifter shaft.
27:32 - Remove shifter forks, how to tell the differences between them.
29:32 - Countershaft Cluster and Bearing Removal
33:45 - Countershaft inspection and pulling the cluster out.
35:02 - Remove the Mainshaft.
37:28 - Remove 3rd gear snap ring.
39:44 - Main Shaft overview
40:37 - Pull out 3rd and 4th gear.
42:42 - Remove of the Mainshaft seal.
45:32 - Remove speedo drive from case.
46:35 - Remove drain bolt.
48:24 - Cleaning, Inspection, and preparation.
53:09 - Rebuild kit overview.
54:02 - Inspecting countershaft cluster.
54:44 - Disassembly of the Mainshaft Cluster.
01:01:10 - Inspect mainsheet and 4th gear.
01:02:16 - Remove mainshaft bearing from outer casing.
01:03:54 - Transmission Top Inspection
01:06:36 - Ratchet mechanism explanation and how it works and removal.
01:09:45 - Remove neutral indicator switch.
01:10:11 - Remove detent follower.
01:11:53 - Remove the shifter drum.
01:15:31 - Disassembly of the Outer Cover.
01:18:46 - Reassembling the Transmission Top.
01:19:32 - Installing the shifter drum aligning timing marks.
01:20:27 - Install shift drum shaft.
01:21:31 - Install ratchet mechanism.
01:22:24 - Align the correct notch in the shaft and plate.
01:25:22 - Install shifter paws and paw carrier.
01:28:11 - Install cover, cover plate and arm.
01:33:10 - Install neutral indicator switch
01:34:14 - Install detent follower.
01:38:48 - Reassembly of Side Kicker Cover
01:39:10 - Install kicker arm.
01:41:23 - Install clutch release arm.
01:46:00 - Install kick arm gear.
01:50:34 - Reassembly of the mainshaft.
01:56:00 - Installing 4th gear into the box.
02:02:45 - Install the main shaft, 3rd gear, and the shifter clutch into the box. Snap ring tip
02:10:10 - Install bearing plate and slinger.
02:13:32 - 4th Gear Seal Install.
02:19:27 - Install main shaft seal.
02:20:43 - Reassembling the Countershaft.
02:23:50 - Prep countershaft.
02:24:34 - Installing the counter shaft cluster and countershaft.
02:35:19 - Installing Mainshaft Starter Gears.
02:40:35 - Install your shifter forks and shifter shaft.
02:44:28 - How to figure out and make sure our shifter forks are centered and adjusting the shifter forks.
02:56:44 - Main Drive Sprocket Installation.
03:03:10 - Reinstalling Transmission Top Cover.
03:03:15 - Reinstall speedo gear.
03:04:20 - Lube Finger Rollers and shifter drum.
03:07:08 - Installing The Side Cover.
03:10:19 - Wooohooo! its back together! Frank's disclaimers.
03:11:43 - Reinstalling The Transmission and Plate Into The Frame.
03:13:35 - Installing the primary cover.
03:16:28 - Put clutch hub on to measure resistants on the main shaft.
03:20:50 - How to make your own shim.
03:25:25 - Explanation of Earlier Transmissions.
03:29:32 - Thats a wrap, finished!
I just skipped going out on a Saturday to watch a 3 and half hour video on how to rebuild a transmission of a bike I don't even own. Time well spent!
LoL, I'm just finishing installing clutch plates on my Honda Shadow 84 750 in my cold garage lol.... He's so much advanced in his job lol....
@@RogerDiotte A well spent Saturday!
This gentleman has been around this stuff for many a year, yiu can tell !
Love these kinda work-study type educational tutorials for gear heads and chopper / bobber / bike fanatics, KEEP EM COMIN' 😊
excellent teaching of a harley 4 speed transmission i am now going to do my 62 panhead gearbox thank you frank
I rebuilt my 1959 transmission a couple of years ago using all new Andrews gears and shafts by watching and learning from another very good video series. Yours has been a review and reminder of all the steps. The explanations here are clear, concise, and no nonsense.
Very well done!
Xx
This video has been a tremendous resource - thank you to all that were involved in making it.
Thank for posting since it a great resource to my 4 speed trans for my 1984 trans FLH that stuck in gear
Great video - thanks! I did notice that when installing the pawl carrier, I found it much easier to put it in without the pawl springs (the little ones that push the pawls up) and then stick them in afterwards that to try to push the pawls in while sliding the carrier over the shifter shaft.
Fantastic stuff…..master mechanic, experienced, tribal knowledge….i learn a shitload from this fella
I enjoyed watching this video, and learned a lot. When ever I need to do the transmission of my 74 shovel this video gave me a head start. Personally I would have used more anti seize / copa slip in case it ever has to be opened again. But that is personal and has nothing to do with the knowlege and craftmanship displayed. 👍👍👍
ruclips.net/video/zzhfvt5vZHI/видео.html
ruclips.net/video/zzhfvt5vZHI/видео.html
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👍👍👍👍 thought i was only guy that counter sunk bolt holes...even on new parts and checked for burs on the everything i build 👍👍
You remind me of my Uncle Al he was an aviation mechanic to roll or 2 and you used to work on motorcycles and airplanes and everyone like that pretty awesome to watch this I learned a lot
Man great video, my 4th gear main seal started to leak on my 84 FXSB and was curious on how to repair it.
I understand better by visualizing, so
Thanks for all the detail you explained!
3 1/2 hours of confidence building. Thanks for the content!
I mic the mainshaft at the high gear bushing and just outboard of that. If there is much difference I put shaft in the lathe and pollish the fat place down to match the bushing area. That way when honing the high gear bushing the correct fit can be achieved.
I took a ratchet top apart with about 80,000 miles and it looked brand new inside. Could not find hardly any wear in it at all. Of course the shifter with pawls springs return springs were replaced, greased and main shaft seal, counter shaft sprocket, throw out bearing replaced and a kick starter added.
Very informative , easy to understand and no picturesque words.
This is the best ratchet top transmission demonstration I have ever seen in 40 years.
ำด
The content was so interesting and well presented the 3 1/2 hours flew by. The repartee between Frank and Mr. White (The parts washer) was as lively as the drama one used to see on American choppers!
Good show.
I would not let the guys on american choppers work on my trans even if you beat me with a 2 x 4.
@@joesurfer9754 I wouldn't even let Mikey take out my trash. Bunch of hacks building trash.
Perfect … I am also working on a 65 that has sat for 20 years … thank you
Nice! I'm working on a 66 that sat for 20 years...
I too am working on a 76 4-speed that has sat for 15 years. This is a good video - thanks. Also great is the series from Tatro Machine on a 4-speed rebuild - lots of "finer points" details.
@@kevinc.9360 Actually..... these guys have a ton of more finess than Tatro. He knows his bikes, but he is slamming everything around for no reason. I can't even watch it.
@@ollelindskog4531 Depends on how you define finesse. Tatro definitely slams things around for no reason a lot. But he goes about things from a machinist's POV as opposed to a mechanic's POV. Slight difference, but you can learn a ton from his knowledge/experience and the depth and detail he goes into.
@@kevinc.9360 I don't really agree. I've been a machinist for 30 years and I've done some things the wrong way and learned 🤣. Sometimes Tatro acts like a damn newbie. Some of the stuff he does in his milling machine is right out dangerous. If it was me, I sure would edit my videos a lot more.
compliments
Awesome video Frank, good info for anyone who actually wants to do their own work.
Thank you for taking the time to show this.
thank you for the in depth video, just wow! do you have any link to that special puller?
Thank you for making such an informative video. I have watched different segments several times and the whole thing at least a couple times.
Thanks again
Exactly what I needed great job thanks I will do it myself!!
Damn, 3 hours of freaking knowledge.
Thank you.
I chose the intersepter over a used bonnie because I didn't want to deal with shim and bucket valve adjustment
This is perfect for everything except the fact it’s lacking an external kickstart spring removal because that one is a tough trick i wish i had
i wish they had You tube videos forty years ago. Man , did i have to learn the hard way. This is very helpful! thanks.
I’ve referenced this video numerous times. Thanks for uploading it!
Those fingernail lengths would drive me crazy. He was an awesome mechanic tho. Great videos. Thank you.
Long video bit the best I've ever seen.
Great content. Thanks for taking the time to produce this. Pulling my 4 speed today.
😢😢😅😢😢😢😢😢😢😢😢😢😅😢😢😢😅😢😅😅😢😅😅😢😅😅😢😢😅😢😅😢😢😢😢😢😅😅😅😅😅😅😅😅😢😢😅😢😢😢😢😢😢😢😢
I would definitely watch it .
Thanks for your time and knowledge Frank. Much appreciated for those of us who are new to 4 speeds.
Excellant instruction excellant filming
12” adjustable wrench…I love it😂
I like these how to videos! Now all we need is an engine video. Maybe a shovel head or Panhead disassembly/rebuild video!
Check out tatro, he’s got a fair bit of tear down and servicing vids. Pacific Mike too
Love these type of video
We can listen to this man all day long! And to Mr white too
Thank you for providing this video. Very interesting - and perfect timing to release this given so many people stuck at home.
Now I’m really interested! Great video thanks!
Thanks Tod this stuff is fantastic. More of this please.
You're a Dying Breed brother Rock on
Very intelligent individual here...
Way to go Frank! Good job!😊
This is fantastic
Very informative visually and explaining the entire procedure ...
You Guys Are The Best on You Tube.
Great video! Do you have a # for the blue Jim’s two piece tool shown in the video. The only one I can find is for a 5 speed and not a 4 speed for that small mainshaft/4th gear seal.
Thanks!
Set screw removed around 19:44 secs of video. Notice in the video the set screw for the shifter rod had not been replaced or reinstalled at time 3:03:26 secs. Can clearly see the threads. Just curious if needed to be put back in place. Just an observation.
He put it back in. It's under the gasket.
You can trust a man with a beard who wares oil staind overalls and dos'nt ware nancy boy latex gloves .Great stuff ;-)
@Edge64 "Then he put the 7 thou in? For what to verify the 7 thou gauge is smaller than the twelve? " Yeah, I was scratching my head on that one.
I agree with both you and Gayle on this topic, mainly because stock stretches, HT studs n bolts don't, it puts more stress on threads ( tearing them out of the block) when you have high compression or overbooked situations.
I'd rather blow out head gaskets, than completely destroy the engine because the head bolts or studs ripped outta the block😂😂😂 besides, the actual metalugists that designed the factory head bolts designed them for expansion and contraction extending engine life and reliability under " normal" which I call sane or " adult driven" use.
Studs are for racers that can afford to fund several back up engines ready to install and lots of backup cash from their sponsors😂😂 so that doesn't come out of pocket.
Normal Joe's like me, want maximum reliability, ease of maintenance, and not spend a billion dollars on rebuilds, I want the wind in my face for years between rebuilds, not 1/4 mile at a time, Harleys weren't designed for that. They were for adventure, long comfortable trips, soaking in the sights and experiences of the open road, and fellowship of like minded people👍💯
good job frank very informative
Noticed that 4th gear was not test fit with the spacer, sprocket, and nut to check for end play prior to putting the main shaft in place. Also, what about end play of 3rd gear too?
Amazing video, thank you for sharing!
Hey my name is Chris I noticed yesterday that what you were changing the oil in the Shovelhead that you used Valvoline SAE oil was that regular automotive oil or was it made for motorcycles
I NEVER put loctite on aluminum threads. Use gasket sealer. it wont come out but if it does it wont take the threads with it. Learned that from an 80 year old working race engine machinist telling me how to stop my exhaust bolt in the head from vibrating out. Has not come lose again in last 20 years. Will someone please buy this guy some drifts.
What type of gasket sealer would you recommend when using as a thread locker in aluminum?
Someone get this guy a muzzle?
How many of these builds are missing the kick starter return spring cover?
I have a '77 4 speed with the 44 loose ball bearings. Does that make it an early model trans? Need to know which Jim's kit to purchase... Thanks!
Give Todd a call on our tech support line 1-855-935-5050 he can better assist you there.
Yous should do a how to on cv carbs I think they are a great carb when set up good and not alot of people no about them or how to tune them
Really enjoyed the video
Frank is the man
The clutch on my ‘77 FXE 4 speed does not engage when cold. So I need a clear strip of road every time I put it in gear and have to warm it up a few times around the block before it loosens up.
Any idea why this is happening? I adjusted the clutch cable correctly and still nothing.
I think this will cover my fx four speed too, mr. Frank. All I ned is some Jims parts I guess
So but did you found out what this pin was from? At 25:30?? I found the same in my Kicker box😢
I have never seen anyone put roller bearings together like that. Use better grease, and put the rollers in the case first.
Just curious as to why the trans wasn’t cleaned in the parts washer before disassembly?
Why do it twice.?
I'm curious, when you use the stone over the gasket areas. Is that something that you learned about in MMI? I'm wondering because my uncle went there in the late 80's and when he passed away a few years ago I inherited his tools. Inside his box with the reamer , hones and so forth he had some knife sharpening stones. I'm now wondering if it's for this exact same thing you was using it for. He always had sharp knives as well but he kept those stones in a certain case.... and also I see your CLUTCH sticker. That's awesome right there :) I seen them 3 times and they always put on a killa show.
Trevor, did your go the one north of Phoenix or the one in Florida. I graduated from Phoenix MMI in '79-80
@@mikeashcraft4354 it was the one in Orlando FL. I just watched this again and I really appreciate you and your knowledge. Thank you.
I love learning about old Harley's... Bitchin video.... Dude is cool as cash....... Philly
At 2:52:20 - look at the mark on the high/drive gear tooth. Ouch.
The only thing missing is now high/4th/drive gear is manufactured with a groove for an o-ring, well at least Andrews does, not sure about anyone else. Or, V-Twin sells the drive gear spacer with an o-ring in the inside. Both of those go a long way to preventing the notorious leak better than any amount of sealer goop.
3:08:00 - No gasket sealer - not buying it. I predict it'll be a weaper pretty quickly even with the honing that was done.
Why would someone throw a fit they've never seen an allen punch? I guarantee those same people have used a wrench hammer or a fist hammer.
Thanks for the walkthrough on this transmission
On my 1974 FL I have to push the heel and toe shifter almost to the floor board to shift. There is very litle play in the linkage going to the top of the tranny. What do you think is worn out in there?
Fantastic video excellent !! ✌
At 56 when pulling off the ratchet gear what’s that tool name or part number for that tool I can’t seem to find it
What is the name of the complete rebuild kit? Where can I get one?
Great video!
Great video
thanks for being you and what you do
Great video and very informative :)
Good job Wes
bossbooil
How much does it weigh if you had to guess? Thanks.
Didn't watch video, just came to see if I can get a response. I wanted to get rid of the Rinky dink oil slinger in my 76 ratchet top, it always Strips out Where it's not spinning. I can't adjust for less clutch or it won't hold it back at a stop In Gear. So I installed an old school Throw out bearing, Had a machine shop make me a super hard push rod the right shorter length. But it just eats the Adjustment screw, (cheap ass aftermarket) I tried the one with the ball bearing and it just seized then eat itself. It's a five finger open primary. Help please.
Great content bro.
This is my type of asmr vid👌👌
Hmm ccvuiu vue cc FCC correction u j Coucu uhh I koi smok I oiiii m out utility hit u Tito u it u it Ivccuvccuciuv thought you
Hey
@@treyneibert5968 yxydyddyyddyydydyddyydydydydydydydyyzdzyddzyzyzyzydydyyddydydydyydydydyddyyddydydyydyddyyydyddydyydydzddyyzddyyddyydyddyyddydyddydyydydydydyddyyddydyydydydydydyddyyyydydydydydyddyyddd
@@finleygniedziejka4114 r
Did you shim up the end play in the cluster shaft? (From an earlier video)
Thanks Frank.
11.01.2023. Дякую Frank.
Hello, could you please tell what does this small ball do on starter clutch 2:36:27, the ball with spring under? Thanks
Hi , no need to answer, I got it !!
Hey @lowbrowcustoms can you guys do a video about rebuilding iron head trans? Sincerely an iron head enthusiast singing the low down broke down Harley Davidson blues.
I think saddletramp has a video on it the problem with iron heads is there’s two different transmissions right and left hand shift
Great video I'm about to do mine, I noticed you use white lith instead of regular grease is there a reason why
Don't use that kind of grease. Use a high quality petroleum based grease, and assembly blue.
Use chip fat....
Good video can you remove and replace main shaft without removing cluster gears?
no
@@alexandercampbell620 I figured it out the hard way. Thanks for your video it was a big help.
Great video. Thanks for putting this out!
Are you going to be selling this video online?
We used to, now it’s just free on here
Nice job guys! This is a great video, getting ready to do mine soon, exactly what I needed. Thanks for passing the knowledge!
Great video, just what i needed to get started restoring my 53 Panhead! Do you have a link or recommendation for the rebuild kit that you were using? Thanks!
He mentions that it is a JIMS kit.
amazing
Thanks
what's the puller separator brand? i didn´t find one similar
Great information , Thanks
Thank you
Frank😎
Interesting... I inquired about the JIMS main shaft seal tool previously, and my questions appears to have disappeared!
At ~2:20:25 in the video is that the 2256 (1 and 2) setup?
CapnDrift yes that seams to be the tool. Just looked up part number on google and looks very similar
@@lowbrowcustoms The numbers are on the tools. I could see 2256-2 on the sleeve, but nothing on the driver. What confuses me is that I contacted JIMS and they told me they didn't have a 4 speed tool. Obviously, the five speed works on the four (shrug).
Great work! Why didn’t you polish up the case when you had it all apart?
Probably because polishing destroys the character of a vintage case.
@@deershack5388 You are correct. Same reason you don't use polishing compound on old coins!
@@deershack5388 Meh. I'm rebuilding the 4-speed from my 76 FX now and am planing some "aggressive cleanup" to give it a slight bit cleaner finish. Not a show polish, not even close, but just a sanding to make it show a little light...