No.
5518-IS Rev B
5-17
A Division of Thiessen Products, Inc.
Instruction Sheet For Tool No. 5518
Shifter Pedal Shaft Bushing Removal and Installation Tool
No. 5518 - Removes and installs shifter bushings on 1985- 3
present rubber mount FLH inner primary housings. 1
TOOLS AND PARTS RECOMMENDED 2
• 3/16” Allen wrench
• 5/8” open end wrench
• Brass hammer
• New Shifter shaft bushings H-D No. 33713-85B - 1985-2000 or 5
No. 42642-00A - 2001-present
• Service Manual for year and model bike being serviced 4
• Press fit lubricant
Wear safety glasses or a full face shield. JIMS is not and cannot be respon- PARTS AVAILABLE SEPARATELY
sible for your safety and quality of your work. If in doubt of any proce- NO. QTY. DESCRIPTION PART NO.
dures, take motorcycle to a qualified motorcycle repair shop. 1 1 REMOVER, SHIFTER SHAFT BUSHING 5518-1
2 1 INSTALLER NUT, SHIFTER SHAFT BUSHING 5518-2
3 1 INSTALLER, SHIFTER SHAFT BUSHING 5518-3
INSTRUCTIONS FOR 1999-PRESENT 4 1 SCREW, 5/16-18X4" BHCS, FULL THREADS 5518-4
1. Remove shifter shaft from inner primary case pivot bore by removing 5 1 WASHER, 5/16” AN 1216
inner and outer shift levers following H-D service manual. 6 1 INSTRUCTION SHEET 5518-IS
2. Using driver No. 5518-1 and brass hammer, drive both bushings out
of inner primary housing toward engine. The bushings will drop out of shifter shaft bore in space between inner
primary and engine. Make sure to pull back driver about 1” and grab first bushing and remove as soon as it has
clearance. Continue driving second bushing until it can clear and drop free.
3. Clean shifter shaft bore in preparation for bushing installation.
4. Apply press fit lubricant to new bushings and make sure bore of inner primary is clean and lightly lubricated.
Lubricate threads of screw No. 5518-4.
5. With a new bushing No. 42462-00A on No. 5518-2 inner installer nut and a new bushing on No. 5518-3 outer
installer, insert screw No. 5518-4 with washer No. 1216 through outer installer and bushing, then through inner
primary bushing bore, through next bushing and thread into No. 5518-2 inner installer nut. Thread screw on until
hand tight and new bushings are just starting into inner primary shifter pivot bore.
6. While holding installer nut No. 5518-2 with a 5/8” wrench, tighten screw No. 5518-4 with 3/16” Allen wrench
until both bushings are installed flush. The inner and outer drivers will bottom out on inner primary housing shifter
shaft bore. Remove bolt, washer, inner, and outer installers.
7. Install shifter shaft with inner and outer shift levers following H-D service manual.
8. Verify transmission shifts properly on bike lift before test riding on public streets.
INSTRUCTIONS FOR 1985-1998 EVOLUTION MODELS
1. Remove shifter shaft from inner primary case pivot bore by removing inner and outer shift levers following H-D serv-
ice manual.
CAUTION: Wear safety glasses over your eyes.
See JIMS® catalog for Hundreds of top quality professional tools.
The last tools you will ever need to buy.
555 Dawson Drive, Camarillo, CA 93012 Phone 805-482-6913 • Fax 805-482-9224 1
Visit us on the web at WWW.JIMSUSA.COM
No.5518-IS Rev B
5-17
A Division of Thiessen Products, Inc.
Instruction Sheet For Tool No. 5518
2. Remove zerk grease fitting from inner primary pivot bore.
3. Using driver No. 5518-1 and brass hammer, drive both bushings out of inner primary housing toward
engine. Pay attention to first bushing, watching to make sure it doesn’t get too close to engine case. When
is about 1/8”-1/16” away, pull driver back about 1” and grab bushing with your fingers. You should be
able to wiggle and remove bushing. The clearance between engine case and inner primary is just enough
to remove first bushing.
4. After first bushing is out, continue driving No. 5518-1 driver, watching to be sure that the tip doesn’t con-
tact engine case. When driver is almost touching case, stop.
5. Clean and lubricate shifter shaft bore and start driving a new lubricated No. 33713-85B bushing into bore.
New bushing will contact old bushing. Continue driving new bushing. It will push old bushing out toward
engine case. When old bushing is about 1/16” from engine case, pull back on driver at least 1”. Grab old
bushing and wiggle it and it will drop free of inner primary shifter boss.
6. Drive first bushing slowly, paying attention to make sure it does not protrude past inner primary shifter boss
bore. Stop when edge is flush to shifter pivot bore.
7. Drive the second bushing in, paying attention to make sure it does not push in past edge of inner primary
bushing bore. Stop when bushing edge is flush with bore of inner primary.
8. Install shifter shaft with inner and outer shift levers following H-D service manual. Install zirk fitting and
lubricate with a grease gun. Pump until grease just starts to appear at edges of pivot shaft bore.
9. Verify transmission shifts properly on bike lift before test riding on public streets.
CAUTION: Wear safety glasses over your eyes.
See JIMS® catalog for Hundreds of top quality professional tools.
The last tools you will ever need to buy.
555 Dawson Drive, Camarillo, CA 93012 Phone 805-482-6913 • Fax 805-482-9224 2
Visit us on the web at WWW.JIMSUSA.COM
