Table of Contents
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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.
(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.
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)
On all models: The oil seal can be removed without removing the primary cover - remove the lever, then use a pick or screwdriver to pry the seal out of the cavity.
The Oil Seal is installed first, followed by the washer/spacer.
Part Description | 1991-1993 P/N | 1994-2003 P/N |
---|---|---|
Shifter Shaft | 34015-91 | |
Primary Cover | 25430-89A+ | 25430-94A+ |
Shaft Bushing | 40520-63 | |
Shaft Oil Seal | 11000101++ | |
Shaft Washer | 7019 |
+__latest P/N
++_latest P/N (orig P/N 37101-84)
On installs, be sure to put tape over the splines on the shifter shaft before installing the oil seal to prevent the splines from cutting the seal.
To increase the tightness of the oil seal (as often suggested by SportsterPaul), after installing the rubber washer, you might install one or two o-rings to take up the gap between the shift lever and the washer. The o-rings do not seal against leaking oil but, instead, they put additional pressure on the oil seal in the primary cover cavity, which does help to seal against leaks.
- Another idea to install the detent plate, is to thread the end of the shaft, then use a nut with blue Loctite. 8)
(Click any picture to see a full-sized version)
Mainshaft Fifth Gear Ball Bearing
1991-1996 Mainshaft 5th Gear Bearing - Used on All Models 9)
- 8996 - Ball Bearing
1997-2005 Mainshaft 5th Gear Bearing - Used on All Models 10)
- 8996A - Ball Bearing
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 Deluxe11) | 27 Teeth | 61 Teeth (Belt) | 127 Teeth (yellow) | 2.26:1 |
1992 | 883 Deluxe12) | 27 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.26:1 |
1991-1992 | 883 & 883 Hug (chain)13) | 21 Teeth | 48 Teeth | Chain driven | 2.29:1 |
1993-1994 | 883 all models14) | 27 Teeth | 61 Teeth | 128 Teeth (orange) | 2.26:1 |
1998 | 883 all15) | 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 | 120016)17) | 29 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.10:1 |
1998 | 1200 all18) | 29 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.10:1 |
Clutch
1991-1994, 1998 Wet Clutch Information 19) 20) 21) | ||
---|---|---|
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)
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.
Year | Internal Gear Ratios | ||||
---|---|---|---|---|---|
US Models | 1st | 2nd | 3rd | 4th | 5th |
1991-1992 All Models 25) | 2.78 | 2.03 | 1.49 | 1.22 | 1.00 |
Year | Overall Gear Ratios | Year | Overall Gear Ratios | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
US Models 883 26) 27)28) | US Models 1200 29) 30)31) |
|||||||||||
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) 32) | 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 | |
Year | Overall Gear Ratios | Year | Overall Gear Ratios | |||||||||
HDI Models 883 33) 34) | HDI Models 1200 35)36) |
|||||||||||
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 | |
Year | Overall Gear Ratios | Year | Overall Gear Ratios | |||||||||
HDI Swiss Models 883 37) | HDI Swiss Models 1200 38) |
|||||||||||
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 screws39) | |
1991 models (1 screw)40) | 50 - 60 in. lbs |
1992 chain drive models (1 screw)41) | 50 - 60 in. lbs |
1992 belt drive models (2 screws)42) | 7 - 9 ft lbs |
1993-1994 models 43) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Transmission sprocket nut (Caution left handed threads)44)45) | 110 - 120 ft lbs (149 - 163 Nm) |
Access door / trapdoor bolts46)47) | 13 - 17 ft lbs (18 - 23 Nm) |
Engine sprocket nut (right hand threads)48)49) | 150 - 165 ft lbs (203 - 224 Nm) |
Clutch hub nut (Caution left handed threads)50)51) | 70 - 80 ft lbs (95 - 108 Nm) |
Sprocket cover screws52)53) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Drain plug54)55) | 14 - 21 ft lbs (19 - 28 Nm) |
Primary cover screws56)57) | 80 - 110 in. lbs (9.0 - 12.4 Nm) |
Primary/ transmission lubricant level screw58)59) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Chain tensioner stud nut60)61) | 20 - 25 ft lbs (27 - 34 Nm) |
Stator Torx fasteners62)63) | 30 - 40 in. lbs (3.4 - 4.5 Nm) |
Neutral indicator switch (91-92)64) | 3 -5 ft lbs |
Shift lever pinch bolt65)66) | 90 - 110 in lbs (10.2 - 12.4 Nm) |
Footrest fasteners67)68) | 16 - 28 ft lbs (22 - 38 Nm) |
Clutch release mechanism screws69)70) | 22 - 30 in lbs (2.5 - 3.4 Nm) |
Inspection (Derby) cover screws71)72) | 40 - 60 in lbs (4.5 - 6.8 Nm) |
Countershaft retaining screw73)74) | 13 - 17 in lbs (18 - 23 Nm) |
1998 Torque Specs
Sprocket nut lock-plate screws75) | 90-110 in-lbs / 10.2-12.4 Nm |
Sprocket nut (caution - left handed threads)76) 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 screws77) | 90-110 in-lbs. (10.2-12.4 Nm) |
Access / trapdoor bolts78) | 13-17 ft-lbs. (18-23 Nm) |
Engine sprocket nut79) | 190-210 ft-lbs. (258-285 Nm) |
Clutch hub nut (caution- left hand threads)80) | 70-80 ft-lbs (95-108 Nm) |
Countershaft retaining screw81) | 13-17 ft-lbs (18-23 Nm) |
Oil Drain plug82) | 14-21 ft-lbs. (19-28 Nm) |
Primary cover Allen Head screws (1/4“x 20 threads)83) | 80-110 in-lbs. (9.0-12.4 Nm) |
Primary chain tensioner stud84) | 20-25 ft-lbs. (27-34 Nm) |
Stator Torx Head screws(1/4”x 20 threads)85) | 30-40 in-lbs. (3.4-4.5 Nm) |
Shift lever pinch bolt86) | 90-110 in-lbs. (10.2-12.4 Nm) |
Clutch inspection (Derby)cover T-27 Torx Head screws87) | 40-60 in-lbs. (4.5-6.8 Nm) |
Footrest Allen Head bolts (5/16“x18)88) | 16-28 ft-lbs. (22-38 Nm) |