Champion reverse gear

[knockdolian]

Well finaly got the reverse kit. Ive been looking at the instructions I have to take the trap door off. Now Im a mechanic. I know what a trap door is and I have removed the transmission through the trap door as a unit. So my question is what does the special tool look like that is mentioned in the instructions and how hard is it to remove the trap door with bearings leaving the shafts in position. Please help before I brake something

 

[Memnoch451]

Well finaly got the reverse kit. Ive been looking at the instructions I have to take the trap door off. Now Im a mechanic. I know what a trap door is and I have removed the transmission through the trap door as a unit. So my question is what does the special tool look like that is mentioned in the instructions and how hard is it to remove the trap door with bearings leaving the shafts in position. Please help before I brake something

First off why didn't you buy the trapdoor puller? Second here is a picture of one for a 6 spd:

Harley Transmission Tool 6 Six Speed Trap Door Puller | eBay

 

[FLTR2008TRIKE]

Well finaly got the reverse kit. Ive been looking at the instructions I have to take the trap door off. Now Im a mechanic. I know what a trap door is and I have removed the transmission through the trap door as a unit. So my question is what does the special tool look like that is mentioned in the instructions and how hard is it to remove the trap door with bearings leaving the shafts in position. Please help before I brake something

If you trike is 2009 and newer. You better re-read the directions on page 2 it specifically say this >>>

WARNING : Do not attempt to push shafts into gearbox or
remove the trap door – This can cause spacers inside the
gearbox to be miss-aligned and lock up the gearbox when
gears are installed and tightened.

Here the pdf file online from Champions website >>

2009>>> http://www.google.com/url?sa=t&rct=...eg-4Ur&usg=AFQjCNGarrLTPcrQvZOWJNWTbstn-PGi6A


Page 2 on 2008 and older >>> http://www.google.com/url?sa=t&rct=...eg-4Ur&usg=AFQjCNGuWdWwIzj38Qg9e5pm7UKCkr0W1Q

Your not removing the gear set to do this only the trap door itself. The special tool you need as per Champion trikes instructions the special tool is for the large gear you have tighten and torque down that goes onto the counter shaft. There are 2 pictures of the snap on tool and champions tool. You need to remove the main shaft nut and the countershaft nuts.

One issue I had with mine is the upper right chrome cover screw would weep some oil. Not sure why but to seal it I put extra clear silicone in the bolt hole to stop it.

 

[Gorilla]

All you are really doing is putting gears on the ends of the 2 shaft. You are not pulling the trans.

 

[flynng]

Everyone is correct. I just put the Champion Reverse on my 08 Ultra with the CSC Daytone kit. Was really easy. Follow instruction. Be carefull with the grinding tool used to cut the sides on the countershaft sprocket. It is very brittle (don't ask how I know). Clean everything well, use the right locktite as described in the instructions. Took about 6 hours from on the lift to on the ground and testing. Everything worked perfect. Only had to adjust the clutch cable. This was the first one I have done. I think a second time would take about 4 hours. You do not remove the trap door on the newer models, only the locknuts on the end of the two shafts. I bought the tool to torque the bigger gear. Not sure why they provide the small gear tool and not the one for the larger gear.

Good luck

 

[THEREALTRIKKY]

If you are doing a 5 speed reverse kit (which I assume you are), you HAVE TO pull the trap door as well. You can purchase the tool from your local harley dealer, or through parts unlimited, etc. If you have access, you can make one using 1/2" plate. This is what I did, as the factory ones, after enough use, i have discovered, tend to bend a bit. If it's a one time use, then buying one locally should suffice just fine!! Just take your time, and read and follow the instructions. You will have to modify your clutch cover a bit as well per the instructions.

 

[knockdolian]

Thanks for the replys. Its an 88 FLHTC. I didn't buy the tool at the time because there is no mention of a tool for pulling the trap door. Infact I was told on this very forum that any special tools were in the kit. I have since looked and the tool looks easy enough to make so thats what I will do. There are plenty on ebay in the US but not in the UK and the post is more than the tool, Unless someone has one they have finished with. Thanks

 

[knockdolian]

Well its on and tested. At last no real dramas. I made the trap door puller. Thanks to all who gave advice. If you are thinking of getting one, go ahead. Riding backwards is interesting.
Thanks again
Paul

 

[Memnoch451]

Well its on and tested. At last no real dramas. I made the trap door puller. Thanks to all who gave advice. If you are thinking of getting one, go ahead. Riding backwards is interesting.
Thanks again
Paul

WTG PAUL. ThumbUp