EVO: Transmission & Final Drive


1991-2003 5-Speed Constant Mesh Wet Clutch Transmission w/Trapdoor

  • The rear compartment of the left and right engine case halves form the transmission housing or case just as in the four speed. An access cover, or trapdoor, is mounted on the left side of the case (inside) behind the primary cover. The main components of the transmission are mounted to this trapdoor to allow you to detach the one cover (together with all the transmission components) for easy removal and servicing without having to split the engine cases in half which otherwise would be a full engine re-build.

98_xls_transmission.jpg1) 98_xls_tranny_installed.jpg2)

(Click any picture to see a full-sized version - Check out this thread about rebuilding the 5-speed transmission: http://xlforum.net/forums/showthread.php?t=1848977)

Overall Gearing is a ratio of the number of engine revolutions to drive the rear wheel one revolution. See the Gearing Chart in this section.

Primary / Transmission fluid capacity is considered 32 oz. (946 ml) when fully dry3) . However, it is typical to only need 28-30oz when replacing the oil. Be sure to refill the cavity so that the level is just above the bottom of the clutch basket.

primary-trans-shifter-91-03.jpg

The shifter components outside the trapdoor:

Shifter Shaft & Shifter Pawl

  • The shifter shaft extends out through the primary cover. The foot shift lever is attached onto the shaft splines at the end. The shifter pawl is attached to the shifter shaft allowing the pawl to pull or push the rotating transmission shifter drum into gear as the shifter shaft rotates. In the detailed picture of the pawl, the shifter detent plate has been removed to show the pawl and the end of the shifter drum with it's four protruding pins.
  • Be sure to carefully adjust the shifter pawl as outlined in the factory service manual. This procedure is critical to center it's travel of movement to create accurate gear shifts. You must use a #32 drill bit for accuracy - no other size works properly. 4)
  • The shifter drum pins are an issue. Due to the engine heat cycles and the constant push and pull by the shifter pawl, the drum pins tend to come out (somewhat) from their mounting holes, causing the detent plate to skew from perpendicular. This causes stress on the detent plate retaining clip and causes excessive wear on the detent plate due to the skew. Whenever the shifter assembly is accessible, these pins should be homed into the shifter drum with a minimal tap on them with a hammer & punch.5)

Shifter Detent Plate, Arm & Spring

  • The detent plate establishes the proper position of the shifter drum to keep the transmission in a particular gear, as well as to define the neutral position. The detent roller lodges between the lobes of the detent plate to resist slipping out of gear or neutral.
  • The original detent plate was upgraded in 1999 (P/N 33656-90A) to provide a more certain engagement of the gears and to make the neutral location easier to find. It is backward compatible. 6)
  • Due to the above mentioned shifter drum pin issue, the OEM spring clip (P/N 11019) is often replaced with an E-clip and a thin washer in order to help the detent plate keep those pins in place.7)

(Click any picture to see a full-sized version)

shifter-detent-plate-91-03.jpg8)shifter-pawl-91-03.jpg9)10)

  • Another idea is to thread the end of the shaft, install the detent plate with a nut with blue Loctite. 11)


Mainshaft Fifth Gear Ball Bearing

1991-1996 Mainshaft 5th Gear Bearing - Used on All Models 12)

  • 8996 - Ball Bearing

1997-2005 Mainshaft 5th Gear Bearing - Used on All Models 13)

  • 8996A - Ball Bearing

Final Drive (Trans to Wheel)

Final Drive Sprocket Torque
Nut DescriptionNut SizeTightening TorqueNotes
1991-92 Chain 1-7/8“ Nut - Left-hand Threads 110-120 ft-lbs Max 150ft-lbs
1991-94 Belt 1-7/8” Nut - Left-hand Threads 110-120 ft-lbs Max 150ft-lbs
1995-03 Belt Tighten to 50ft-lbs, then add 30°-40° more rotation
(use only 2 or 3 drops of RED threadlocker on this nut)
Be sure to use a sprocket locking tool when removing or installing the Sprocket Nut
Year883 Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
1991883 Deluxe14)27 Teeth61 Teeth (Belt)127 Teeth (yellow)2.26:1
1992883 Deluxe15)27 Teeth61 Teeth (Belt)128 Teeth (orange)2.26:1
1991-1992883 & 883 Hug (chain)16)21 Teeth48 TeethChain driven2.29:1
1993-1994883 all models17)27 Teeth61 Teeth128 Teeth (orange)2.26:1
1998883 all18) 27 Teeth61 Teeth (Belt)128 Teeth (orange)2.26:1
Year1200 Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
1991-1994120019)20)29 Teeth61 Teeth (Belt)128 Teeth (orange)2.10:1
19981200 all21)29 Teeth61 Teeth (Belt)128 Teeth (orange)2.10:1


Clutch

1991-1994, 1998 Wet Clutch Information 22) 23) 24)
Clutch plate thicknessFriction plate (fiber)0.0866 in. (± 0.0031 in.) / (2.200 mm ± 0.079 mm)
Steel plate0.0629 in. (± 0.0020 in.) / (1.598 mm ± 0.51 mm)
Maximum allowable warp-age–Friction (fiber) plate 0.0059 in. / (0.150 mm)
–Steel plate 0.0059 in. / (0.150 mm)
Clutch pack service wear limit0.6610 in. min. / (16.787 mm)

Primary Drive (engine to transmission)

YearDomestic ModelEngine SprocketClutch SprocketRatio
1991-1994 25)26)All Models35 Teeth56 Teeth1.60:1
1998 27)All Models35 Teeth56 Teeth1.60:1

Transmission

  • Internal Gear Ratios are the number of clutch gear revolutions to drive the mainshaft sprocket one revolution.
  • Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution.
YearInternal Gear Ratios
US Models1st2nd3rd4th5th
1991-1992 All Models 28)2.782.031.491.221.00
YearOverall Gear RatiosYearOverall Gear Ratios
US Models
883 29) 30)31)
US Models
1200 32) 33)34)
1st2nd3rd4th5th 1st2nd3rd4th5th
1991-1992 883, 883 Hug 10.167.415.444.453.66 1991-19949.356.825.014.093.36
1991-1992 883 Deluxe
1993-1994 883 (All) 35)
10.047.325.384.393.61
1998 8839.717.125.184.263.61 1998 12009.046.624.823.973.36
YearOverall Gear RatiosYearOverall Gear Ratios
HDI Models
883 36) 37)
HDI Models
1200 38)39)
1st2nd3rd4th5th 1st2nd3rd4th5th
1993-1994 8839.717.125.184.263.61 1993-19949.046.624.823.973.36
1998 8839.717.125.184.263.61 1998 12009.046.624.823.973.36
YearOverall Gear RatiosYearOverall Gear Ratios
HDI Swiss Models
883 40)
HDI Swiss Models
1200 41)
1st2nd3rd4th5th 1st2nd3rd4th5th
1993-19949.056.604.853.963.25 1993-19948.436.144.513.683.03

Fastener Torque Specs

1991-1994 Torque Specs

Transmission sprocket nut locking screws42)
1991 models (1 screw)43)50 - 60 in. lbs
1992 chain drive models (1 screw)44)50 - 60 in. lbs
1992 belt drive models (2 screws)45)7 - 9 ft lbs
1993-1994 models 46)90 - 110 in. lbs (10.2 - 12.4 Nm)
Transmission sprocket nut (Caution left handed threads)47)48)110 - 120 ft lbs (149 - 163 Nm)
Access door / trapdoor bolts49)50)13 - 17 ft lbs (18 - 23 Nm)
Engine sprocket nut (right hand threads)51)52)150 - 165 ft lbs (203 - 224 Nm)
Clutch hub nut (Caution left handed threads)53)54)70 - 80 ft lbs (95 - 108 Nm)
Sprocket cover screws55)56)90 - 110 in. lbs (10.2 - 12.4 Nm)
Drain plug57)58)14 - 21 ft lbs (19 - 28 Nm)
Primary cover screws59)60)80 - 110 in. lbs (9.0 - 12.4 Nm)
Primary/ transmission lubricant level screw61)62)90 - 110 in. lbs (10.2 - 12.4 Nm)
Chain tensioner stud nut63)64)20 - 25 ft lbs (27 - 34 Nm)
Stator Torx fasteners65)66)30 - 40 in. lbs (3.4 - 4.5 Nm)
Neutral indicator switch (91-92)67)3 -5 ft lbs
Shift lever pinch bolt68)69)90 - 110 in lbs (10.2 - 12.4 Nm)
Footrest fasteners70)71)16 - 28 ft lbs (22 - 38 Nm)
Clutch release mechanism screws72)73)22 - 30 in lbs (2.5 - 3.4 Nm)
Inspection (Derby) cover screws74)75)40 - 60 in lbs (4.5 - 6.8 Nm)
Countershaft retaining screw76)77)13 - 17 in lbs (18 - 23 Nm)

1998 Torque Specs

Sprocket nut lock-plate screws78)90-110 in-lbs / 10.2-12.4 Nm
Sprocket nut (caution - left handed threads)79)
50 ft-lbs. (67.8 Nm) initially
Tighten an additional 30-40 degrees
Install lock plate over sprocket nut to align to two opposite threaded mounting holes
Tighten sprocket nut additionally if holes don't match up but not to exceed 45 degrees total
Sprocket cover screws80)90-110 in-lbs. (10.2-12.4 Nm)
Access / trapdoor bolts81)13-17 ft-lbs. (18-23 Nm)
Engine sprocket nut82)190-210 ft-lbs. (258-285 Nm)
Clutch hub nut (caution- left hand threads)83)70-80 ft-lbs (95-108 Nm)
Countershaft retaining screw84)13-17 ft-lbs (18-23 Nm)
Oil Drain plug85)14-21 ft-lbs. (19-28 Nm)
Primary cover Allen Head screws (1/4“x 20 threads)86)80-110 in-lbs. (9.0-12.4 Nm)
Primary chain tensioner stud87)20-25 ft-lbs. (27-34 Nm)
Stator Torx Head screws(1/4”x 20 threads)88)30-40 in-lbs. (3.4-4.5 Nm)
Shift lever pinch bolt89)90-110 in-lbs. (10.2-12.4 Nm)
Clutch inspection (Derby)cover T-27 Torx Head screws90)40-60 in-lbs. (4.5-6.8 Nm)
Footrest Allen Head bolts (5/16“x18)91)16-28 ft-lbs. (22-38 Nm)

1) , 2)
HD 5 speed transmission / photo by hippysmack of the XLFORUM
3)
HD XLH FSM
6)
See Reddtigger's comments in this thread - http://xlforum.net/forums/showthread.php?t=222357
8) , 10)
Annotated by IXL2Relax at the XLForum
9)
Image from Cattywampus XLForum Threadid=586780
12)
91-96 HD Sportster Parts Catalogs
13)
97-05 HD Sportster Parts Catalogs
14) , 16)
1991 HD Sportster FSM pg 6-1
15) , 19) , 25) , 28) , 29) , 32)
1991-1992 HD Sportster FSM pg 6-1
17) , 20)
1993-1994 HD FSM pg 6-1
18) , 21) , 27)
1998 HD XLH FSM pg 6-1
22)
1991-1992 HD FSM pg 6-2
23)
1993-1994 HD FSM pg 6-2
24)
1998 HD FSM pg 6-2
26) , 30) , 33) , 35) , 36) , 38) , 40) , 41)
1993-1994 HD Sportster FSM pg 6-1
31) , 34) , 37) , 39)
1998 Sportster FSM pg 6-1
42) , 43) , 44) , 45) , 47) , 49) , 51) , 53) , 55) , 57) , 59) , 61) , 63) , 65) , 67) , 68) , 70) , 72) , 74) , 76)
1991-1992 HD Sportster FSM pg 6-2
46) , 48) , 50) , 52) , 54) , 56) , 58) , 60) , 62) , 64) , 66) , 69) , 71) , 73) , 75) , 77)
1993-1994 HD Sportster FSM pg 6-2
78) , 79) , 80) , 81) , 82) , 83) , 84) , 85) , 86) , 87) , 88) , 89) , 90) , 91)
1998 HD XLH FSM pg 6-2
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