This Video is brought to you by Lowbrow Customs https://www.lowbrowcustoms.com

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: https://www.lowbrowcustoms.com/collec...

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 - https://www.lowbrowcustoms.com/collec...
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!