Its my first time breaking down on a bike and I have a garage full of tools so I figured "how hard could this be" Got me a manual and had at it. I don't have a lot of knowledge on aftermarket/stock parts and most of the guys I ride with are the bring it to the dealership type. IM not about to dump all that scratch on shop labor costs!

 

A pulley from Andrews will run about $150. May find them cheaper on eBay, but not by much.
You haven't said what year and model you're working on.

 

'02 Springer

 

What does the transmission main drive gear spline look like?

 

It does not appear to have wear. I was trying to find depth of spline so I could mic it to make sure. The lock ring broke under the 1 7/8" nut. From what Ive read is that that nut is a pain to remove. Mine wasn't that bad so Im thinking it had loosened up a bit and that was the cause for the spline being taken out.


But then again, since this is my first time taking anything apart on my bike.... I may be way off on the root cause.




I want to say thank you to those that are trying to help.

 

I figured the big nut got loose or someone did not torque it and lock it properly. You should be able to eyeball the spline (it's actually called a serration since a spline it angled side but flat and a serration is convex profile ) Serrations actually are stronger than splines, the fits are closer and they are easier to produce accurately. You may have enough of the OD behind the serration if you can see it. When you put the new pulley on, there should be no shake. Hard to believe it's not damaged. it has to go out back side of transmission..so the job may be getting bigger.. Here's a diameter I am referring to on a Baker picture.. I am guessing, that pulley is cast iron maybe, Sure the drive gear is better steel and why it looks OK.

 

If this job gets that big, them Im 6 speeding it!!!!

 

You are adding K's to the price tag..Sure Mr. Baker can fix you up with a Forum discount. He's on here all the time and probably know what to look for in ckecking you part......Where are you Mark?

 

Usually because of the hardness of the main drive gear the pulley will strip out first. Just make sure the splines are not rounded and the new pulley fits snug. Stay away from aluminum for street use they won't last. If you decide to go 6 speed the part number for your bike will be DD411PL they retail for $2495. Forum members get 10% off which would bring it down to $2245.50. If you can post a pic of the main drive gear we can take a look at it.

 

By any chance do you have the major/minor diameter of the main shaft spline?