1. Long shift shaft
2. 5th and 6th gear shifter fork
3. 5th gear
4. Short shift shaft
5. 4th gear
6. 3rd and 4th gear shifter fork
7. 3rd gear
8. 2nd gear
9. 1st and 2nd gear shifter fork
10. 1st gear
Figure 7-31.Transmission Gears and Shifter Forks
INSTALLATION
1. Cover mainshaft clutch hub splines with tape to prevent
the splines damaging the main drive gear oil seal.
2. Verify that two ring dowels are in place on side door flange.
place a new gasket on the ring dowels.
3. Apply clean transmission lubricant to the main drive gear
bearings.
NOTE
Be sure the transmission filler plug/dipstick is removed before
installing transmission assembly. Contact with the filler
plug/dipstick will prevent installation of transmission assembly.
4. Install the transmission assembly in the transmission case.
5. If equipped, place exhaust bracket into position. Install
side door fasteners.
6. See Figure 7-32. Using crosswise pattern, tighten all side
door hardware (1, 2) to 13-18 ft-lbs (17.6-24.4 Nm).
1. Stud
2. Bolt
Figure 7-32. Side Door Hardware
7. Install mainshaft bearing inner race. See 6.6 TRANSMIS-
SION SPROCKET.
8. See Figure 7-7. Install push rod assembly (items 2-5) in
mainshaft hole. Secure with new retaining ring (1) if
removed.
NOTE
The two top side cover fasteners are shorter in length than the
others.
9. Install the clutch release cover, using a new gasket. See
7.4 CLUTCH RELEASE COVER.
10. Remove shifter cam pawl from top cover gasket surface
and place on shift cam. Install new transmission top cover
gasket. Install transmission top cover. Install top cover
fasteners and tighten to 84-132 in-lbs (9.5-14.9 Nm).
11. Install vent hose to top cover fitting, if removed.
12. See Figure 7-26. Install new o-ring (7) on oil spout (6).
Apply clean engine oil to o-ring. Push oil spout into trans-
mission case. Install oil spout fastener (8).Tighten fastener
to 84-132 in-lbs (9.5-14.9 Nm).
13. Install transmission sprocket nut. See 6.6 TRANSMISSION
SPROCKET.
14. Install primary chaincase, clutch assembly and primary
cover. See 6.2 PRIMARY CHAINCASE COVER, Installa-
tion.
15. Replace o-ring on plug. Clean and install transmission
drain plug.Tighten to 14-21 ft-lbs (19.0-28.5 Nm).
16. Fill transmission to proper level with fresh transmission
fluid. See 1.10 TRANSMISSION LUBRICANT.
17. Install exhaust system. See 4.16 EXHAUST SYSTEM.
7-18 2008 Dyna Service: Transmission
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