EVO: Transmission & Final Drive


2004+ 5-Speed Constant Mesh Transmission w/o Trapdoor

  • For 2004 and up models, HD redesigned the transmission / engine case to confine the transmission fully within the engine cases. The trapdoor (access plate), that previously allowed easy removal of the transmission for service, was eliminated. Now, in order to service the transmission components, the engine cases need to be split.

Shifter Assembly - typical of 04-later 1)

2004-2005 vs 2006+ Shifter Assembly Note the following part number differences between 04-05 and 06-later. The 06-later shifter shaft is larger than the previous version and therefore the hole in the primary cover is larger & the bushing & oil seal is different.

Part Description 2004-05 P/N 2006-2007 P/N 2008-later P/N
Shifter Assembly 34014-02B 34014-06A
Primary Cover 25460-04 25460-06
Shaft Bushing+ 40520-63 40574-06A
Shaft Seal+ 11000101++ 37107-06
Shaft Washer 7019 7019 7080

+__06-later - The outer diameter of the seal is larger, the bushings have a shoulder and press in from the inside of the cover. 2)
++_latest P/N (orig P/N 37101-84)



Clutch

2004 Wet Clutch Information 3)
Clutch plate thickness–Friction 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 Model(s)Engine SprocketClutch SprocketRatio
2004883, 883C4) 34 Teeth57 Teeth1.676:1
1200C, 1200R5)38 Teeth57 Teeth1.500:1
YearHDI, Japan Model(s)Engine SprocketClutch SprocketRatio
2004883, 883C6) 38 Teeth57 Teeth1.500:1
1200C, 1200R7)38 Teeth57 Teeth1.500:1

Transmission

YearOverall Gear Ratios8) Overall Gear Ratios9)
US Models 883 US Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
200410.9447.5245.8344.8064.071 9.4546.5005.0404.1523.517
YearOverall Gear Ratios10) Overall Gear Ratios11)
HDI Models 883 HDI Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
20049.7926.7325.2204.3013.643 9.1396.2834.8724.0143.400
YearOverall Gear Ratios12) Overall Gear Ratios13)
Japan Models 883 Japan Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
20049.6476.6335.1434.2483.643 9.0046.1904.8003.9653.400

Mainshaft Fifth Gear Ball Bearing

1997-2005 Mainshaft 5th Gear Bearing - Used on All Models 14)

  • 8996A - Ball Bearing

2006 and later Mainshaft 5th Gear Bearing - Used on All Models (except XR-1200 / XR1200X) 15)

  • 8964 - Ball Bearing

Mainshaft 5th Gear Bearing - Used on XR-1200 and XR1200 Models 16)

  • 8956 - Ball Bearing
  • Accompanied with:
    • 11631 - O-ring
    • 33354-08 - Spacer

Final Drive (Trans to Rear Wheel)

YearDomestic Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
2004883/ 883C28 Teeth68 Teeth136 Teeth2.429:1
1200/ 1200R29 Teeth68 Teeth137 Teeth2.345:1
YearHDI / Japan Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
2004883 / 883C28 Teeth68 Teeth136 Teeth2.429:1
1200 / 1200R30 Teeth68 Teeth137 Teeth2.267:1


3)
2004 HD FSM pg 6-2
4) , 5) , 6) , 7)
2004 HD Sportster FSM pg 6-1
8) , 9) , 10) , 11) , 12) , 13)
Number of engine revolutions to drive rear wheel one revolution.
14)
04-05 HD Sportster Parts Catalogs
15)
06 and up HD Sportster Parts Catalogs
16)
09 and up HD Sportster Parts Catalogs
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