EVO: Transmission & Final Drive

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====== EVO: Transmission & Final Drive ======




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====== 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.

{{techtalk:evo:transfinal:98_xls_transmission.jpg?direct&300}}((HD 5 speed transmission / photo by hippysmack of the XLFORUM)) {{techtalk:evo:transfinal:98_xls_tranny_installed.jpg?direct&300}}((HD 5 speed transmission / photo by hippysmack of the XLFORUM))

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

|Below are the dry recommendations from the MoCo. However, as stated above, the proper level is just above the clutch basket.
 
|add fluid chart when finished

{{techtalk:evo:transfinal:primary-trans-shifter.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. ((http://xlforum.net/vbportal/forums/showthread.php?threadid=29016))
  * 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 retaining detent plate retaining clip and wears 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.((http://xlforum.net/vbportal/forums/showthread.php?t=1675146))

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 (33656-90A) to provide a more certain engagement of the gears and to make the neutral location easier to find. It is backward compatible. ((See Reddtigger's comments in this thread - http://xlforum.net/vbportal/forums/showthread.php?t=222357))
  * Due to the above mentioned shifter drum pin issue, the OEM spring clip is often replaced with an E-clip and a thin washer in order to help the detent plate keep those pins in place.((http://xlforum.net/vbportal/forums/showthread.php?t=1675146))

{{techtalk:evo:transfinal:shifter-detent-plate.jpg?400}}{{techtalk:evo:transfinal:shifter-pawl.jpg?400}}(Click any picture to see a full-sized version)

===== Final Drive (Trans to Wheel) =====

^Final Drive Sprocket Torque ||||||
^Nut Description^Nut Size^Tightening Torque^Notes|||
| 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 ||||||
^Year^883 Model(s)^Transmission Sprocket^Rear Wheel Sprocket^Secondary Drive Belt^Ratio^
|1991|883 Deluxe((1991 HD Sportster FSM pg 6-1))|27 Teeth|61 Teeth (Belt)|127 Teeth (yellow)|2.26:1|
|1992|883 Deluxe((1991-1992 HD Sportster FSM pg 6-1))|27 Teeth|61 Teeth (Belt)|128 Teeth (orange)|2.26:1|
|1991-1992|883 & 883 Hug (chain)((1991 HD Sportster FSM pg 6-1))|21 Teeth|48 Teeth|Chain driven|2.29:1| 
|1993-1994|883 all models((1993-1994 HD FSM pg 6-1))|27 Teeth|61 Teeth|128 Teeth (orange)|2.26:1|
|1998|883 all((1998 HD XLH FSM pg 6-1)) |27 Teeth|61 Teeth (Belt)|128 Teeth (orange)|2.26:1|
^Year^1200 Model(s)^Transmission Sprocket^Rear Wheel Sprocket^Secondary Drive Belt^Ratio^
|1991-1994|1200((1991-1992 HD Sportster FSM pg 6-1))((1993-1994 HD FSM pg 6-1))|29 Teeth|61 Teeth (Belt)|128 Teeth (orange)|2.10:1|
|1998|1200 all((1998 HD XLH FSM pg 6-1))|29 Teeth|61 Teeth (Belt)|128 Teeth (orange)|2.10:1|




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===== Clutch =====

 
^  1991-1994, 1998 Wet Clutch Information ((1991-1992 HD FSM pg 6-2)) ((1993-1994 HD FSM pg 6-2)) ((1998 HD FSM pg 6-2))  ^^^
|Clutch plate thickness|Friction plate (fiber)|0.0866 in. (± 0.0031 in.) / (2.200 mm ± 0.079 mm)|
|    |Steel plate|0.0629 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 limit|0.6610 in. min. / (16.787 mm)|



 
  

 


===== Primary Drive (engine to transmission) =====

^Year^Domestic Model^Engine Sprocket^Clutch Sprocket^Ratio^
|1991-1994 ((1991-1992 HD Sportster FSM pg 6-1))((1993-1994 HD Sportster FSM pg 6-1))|All Models|35 Teeth|56 Teeth|1.60:1|
|1998 ((1998 HD XLH FSM pg 6-1))|All Models|35 Teeth|56 Teeth|1.60:1|



===== Transmission =====
 

^Year^Internal Gear Ratios ((Number of clutch gear revolutions to drive mainshaft sprocket one revolution.))^^^^^
^US Models|1st|2nd|3rd|4th|5th|
|1991-1992 All Models ((1991-1992 HD Sportster FSM pg 6-1))|2.78|2.03|1.49|1.22|1.00|



^Year^Overall Gear Ratios((Number of engine revolutions to drive rear wheel one revolution.))^^^^^    ^Overall Gear Ratios((Number of engine revolutions to drive rear wheel one revolution.))^^^^^^
^    ^  US Models  883 ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  ||||^     ^  US Models  1200 ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  ||||||
^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th|
|1991-1992 883, 883 Hug  |10.16|7.41|5.44|4.45|3.66^   |1991-1994|9.35|6.82|5.01|4.09|3.36|
|1991-1992 883 Deluxe \\ 1993-1994 883 (All) ((1993-1994 HD Sportster FSM pg 6-1)) | 10.04|7.32|5.38|4.39|3.61^    |
|1998 883|9.71|7.12|5.18|4.26|3.61^    |1998 1200|9.04|6.62|4.82|3.97|3.36|
^    ^  HDI Models  883 ((1993-1994 HD Sportster FSM pg 6-1)) ((1998 Sportster FSM pg 6-1))  ||||^     ^  HDI Models  1200 ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))    ||||||
^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th|
|1993-1994 883|9.71|7.12|5.18|4.26|3.61^ |1993-1994|9.04|6.62|4.82|3.97|3.36|
|1998 883|9.71|7.12|5.18|4.26|3.61^    |1998 1200|9.04|6.62|4.82|3.97|3.36|
^    ^  HDI Swiss Models  883 ((1993-1994 HD Sportster FSM pg 6-1))  ||||^     ^  HDI Swiss Models  1200 ((1993-1994 HD Sportster FSM pg 6-1))   ||||||
^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th|
|1993-1994|9.05|6.60|4.85|3.96|3.25^   |1993-1994|8.43|6.14|4.51|3.68|3.03|


===== Fastener Torque Specs =====

==== 1991-1994 Torque Specs ====

|Transmission sprocket nut locking screws((1991-1992 HD Sportster FSM pg 6-2))||
|1991 models (1 screw)((1991-1992 HD Sportster FSM pg 6-2))|50 - 60 in. lbs|
|1992 chain drive models (1 screw)((1991-1992 HD Sportster FSM pg 6-2))|50 - 60 in. lbs|
|1992 belt drive models (2 screws)((1991-1992 HD Sportster FSM pg 6-2))|7 - 9 ft lbs|
|1993-1994 models ((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)|
|Transmission sprocket nut (**Caution left handed threads**)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|110 - 120 ft lbs (149 - 163 Nm)|
|Access door / trapdoor bolts((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|13 - 17 ft lbs (18 - 23 Nm)|
|Engine sprocket nut (right hand threads)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|150 - 165 ft lbs (203 - 224 Nm)|
|Clutch hub nut (**Caution left handed threads**)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|70 - 80 ft lbs (95 - 108 Nm)| 
|Sprocket cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)|
|Drain plug((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|14 - 21 ft lbs (19 - 28 Nm)|
|Primary cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|80 - 110 in. lbs (9.0 - 12.4 Nm)|
|Primary/ transmission lubricant level screw((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)|
|Chain tensioner stud nut((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|20 - 25 ft lbs (27 - 34 Nm)|
|Stator Torx fasteners((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|30 - 40 in. lbs (3.4 - 4.5 Nm)|
|Neutral indicator switch (91-92)((1991-1992 HD Sportster FSM pg 6-2))|3 -5 ft lbs|
|Shift lever pinch bolt((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in lbs (10.2 - 12.4 Nm)|
|Footrest fasteners((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|16 - 28 ft lbs (22 - 38 Nm)|
|Clutch release mechanism screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|22 - 30 in lbs (2.5 - 3.4 Nm)|
|Inspection (Derby) cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|40 - 60 in lbs (4.5 - 6.8 Nm)|
|Countershaft retaining screw((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|13 - 17 in lbs (18 - 23 Nm)|

==== 1998 Torque Specs ====

|Sprocket nut lock-plate screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs / 10.2-12.4 Nm|
|Sprocket nut (**caution - left handed threads**)((1998 HD XLH FSM pg 6-2)) \\ 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 screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 Nm)|
|Access / trapdoor bolts((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs. (18-23 Nm)|
|Engine sprocket nut((1998 HD XLH FSM pg 6-2))|190-210 ft-lbs. (258-285 Nm)|
|Clutch hub nut (**caution- left hand threads**)((1998 HD XLH FSM pg 6-2))|70-80 ft-lbs (95-108 Nm)|
|Countershaft retaining screw((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs (18-23 Nm)|
|Oil Drain plug((1998 HD XLH FSM pg 6-2))|14-21 ft-lbs. (19-28 Nm)| 
|Primary cover Allen Head screws (1/4"x 20 threads)((1998 HD XLH FSM pg 6-2))|80-110 in-lbs. (9.0-12.4 Nm)|
|Primary chain tensioner stud((1998 HD XLH FSM pg 6-2))|20-125 ft-lbs. (27-34 Nm)|
|Stator Torx Head screws(1/4"x 20 threads)((1998 HD XLH FSM pg 6-2))|30-40 in-lbs. (3.4-4.5 Nm)|
|Shift lever pinch bolt((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 Nm)|
|Clutch inspection (Derby)cover T-27 Torx Head screws((1998 HD XLH FSM pg 6-2))|40-60 in-lbs. (4.5-6.8 Nm)|
|Footrest Allen Head bolts (5/16"x18)((1998 HD XLH FSM pg 6-2))|16-28 ft-lbs. (22-38 Nm)|



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