Differences
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techtalk:evo:transfinal04 [2021/05/16 02:29] ixl2relax [Mainshaft Fifth Gear Ball Bearing] |
techtalk:evo:transfinal04 [2024/01/09 02:13] hippysmack |
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| ===== Shifter Assembly ===== | ===== Shifter Assembly ===== | ||
| - | {{:techtalk:evo:transfinal:shifter-assemby-04later.jpg?400|}}((pic from AB,Frank http://xlforum.net/forums/showthread.php?t=1799188)) {{:techtalk:evo:transfinal:shiftershaft-oilseal-37107-06-manborn.jpg?400|}} {{:techtalk:evo:transfinal:shiftershaft-bushing-40574-06.jpg?200|}} | + | {{:techtalk:evo:transfinal:shifter-assemby-04later.jpg?400|}}((pic from AB,Frank https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/167512-primary-rattle-noises-wtf-now?t=1799188)){{:techtalk:evo:transfinal:shiftershaft-oilseal-37107-06-manborn.jpg?400|}}{{:techtalk:evo:transfinal:shiftershaft-bushing-40574-06.jpg?200|}} |
| **2004-2005 vs 2006+ Shifter Assembly**\\ | **2004-2005 vs 2006+ Shifter Assembly**\\ | ||
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| the previous version and therefore the hole in the primary cover is larger & the bushing & oil seal is different. | 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 | | + | ^ Part Description ^ 2004-05 P/N ^ 2006-later P/N | |
| - | | Shifter Assembly | 34014-02B | 34014-06A || | + | | Shifter Assembly | 34014-02B | 2006-2008 ---- 34014-06\\ 2009-later --- 34014-06A | |
| - | | Shaft Bushing+ | 40520-63 | 40574-06A || | + | | Shaft Bushing+ | 40520-63 | 40574-06A | |
| - | | Shaft Oil Seal+ | 11000101++ | 37107-06 || | + | | Shaft Oil Seal+ | 11000101++ | 37107-06 | |
| - | | Shaft Washer | 7019 | 7019 | 7080 | | + | | Shaft Washer | 7019 | 2006-2007 ---- 7019\\ 2008-later ---- 7080 | |
| - | ^ ^ 04-05 Primary Covers P/N ^ 06-later Primary Covers P/N || | + | ^ ^ 04-05 Primary Covers P/N ^ 06-later Primary Covers P/N | |
| - | | The 04-05 covers\\ are not inter-\\ changeable with\\ the 06+ versions | Polished - 25430-04\\ Chrome - 25460-04\\ Silver - 25471-04\\ Black - 25307-05 ('05) | Polished - 25430-06\\ Chrome - 25460-06\\ Silver - 25471-06\\ Black - 25307-06\\ Grey - 60830-07 ('07+) || | + | | The 04-05 covers\\ are not inter-\\ changeable with\\ the 06+ versions | Polished - 25430-04\\ Chrome - 25460-04\\ Silver - 25471-04\\ Black - 25307-05 ('05) | Polished - 25430-06\\ Chrome - 25460-06\\ Silver - 25471-06\\ Black - 25307-06\\ Grey - 60830-07 ('07+) | |
| - | | All of these may have the same Internal Casting # 34951-04 which can be confusing |||| | + | | All of these may have the same Internal Casting # 34951-04 which can be confusing ||| |
| - | +__06-later - The outer diameter of the seal is larger, the bushings have a shoulder and press in place from the inside of the cover. ((oo_buck_us in Post#15 - http://xlforum.net/forums/showthread.php?t=1560232))\\ | + | +__06-later - The outer diameter of the seal is larger, the bushing has a shoulder and presses in place from the inside of the cover. ((oo_buck_us in Post#15 - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/143966-04-primary-cover-on-an-07?t=1560232))\\ |
| - | ++_latest P/N (orig P/N 37101-84)\\ | + | ++_latest P/N is 11000101 with 'garter spring' inside (old P/N 37101-84/A/B - no spring). Dims per James Gasket - 13 x 19 x 4\\ |
| + | ... Cometic Equiv of 11000101 is C10213\\ | ||
| - | \\ | + | ===== The Shifter Shaft Seal ===== |
| - | On all models: | + | **Install 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 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\\ | ||
| - | (NOTE that the parts manual for 2004 & 2005 shows the Rubber Washer installed first & then the Oil Seal - but this is **WRONG!**) | ||
| On installs, make sure the shaft is free from debris or rust and 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. | On installs, make sure the shaft is free from debris or rust and 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. | + | {{:techtalk:evo:transfinal:wire_brush_shifter_shaft_by_cjburr.jpeg?direct&335|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install?t=49915)) {{:techtalk:evo:transfinal:shiftershaft-tapeoversplines-manborn.jpg?335|}} \\ |
| + | |||
| + | The Oil Seal is installed first, followed by the washer/spacer (the '04-'05 Parts Manual may show the **WRONG** order).\\ | ||
| + | |||
| + | NOTE: There is a [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tsb1350.pdf|TSB (M-1350)]] related to the 'NEW' Shifter Shaft Seal P/N 11000101 being installed with Special Tool HD-51337. The new seal has a 'garter spring' to help seal the shifter shaft from leaks. In this TSB, the following caution is made: If the tool is not used, install seal to a depth of 0.125-0.135 inches. DO NOT bottom the seal in the bore. Bottoming the seal will damage it and prevent it from sealing properly. (While this bulletin refers to Big Twins with 6-spd transmissions, this shifter shaft seal is used on other models, including the Sportsters.) | ||
| - | {{:techtalk:evo:transfinal:wire_brush_shifter_shaft_by_cjburr.jpeg?direct&335|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=49915)) {{:techtalk:evo:transfinal:shiftershaft-tapeoversplines-manborn.jpg?335|}} \\ | + | The idea is that if you bottom the seal, the lips around the shaft will be pressed tightly against the primary cover and will not allow the lips to smoothly follow the movement of the shaft. Thus, the tight lips will be thwarting the 'sealing' aspect that the 'garter spring' is designed to enhance. |
| - | {{:techtalk:evo:transfinal:shiftershaft-oringmod-4pac.jpg?400|}} \\ | + | The clearance should be from the deepest edge of the seal cavity in the primary cover. The referenced instructions are for the BT models. Therefore, the Sportster models may not be exactly the same. |
| + | |||
| + | BUT, the principle still applies: Insert the seal slightly below that deepest edge of the cavity and don't bottom out the seal. That gives it the best chance to work correctly. | ||
| + | |||
| + | NOTE: Some owners have mistakenly gotten 2006-later covers and installed on 2004-05 engines. Neither stock shifter shaft seals would fit correctly, but purchasing an aftermarket seal, 12mm x 22mm x 5mm R23, seems to fit.((See post#15 from 93trident of the XLForum - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/202496-what-s-that-about-then?t=2079676)) | ||
| + | |||
| + | Also see the Sportsterpedia Primary Cover info [[techtalk:evo:priclutch02|HERE]]. | ||
| + | |||
| + | 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. (But be sure you are installing the seal correctly as mentioned above, not bottoming in the bore.) | ||
| + | |||
| + | {{:techtalk:evo:transfinal:shiftershaft-oringmod-4pac.jpg?400|}} {{:techtalk:evo:transfinal:06-21-shiftershaft-oilseal-bushing-bore.jpg?400|}}\\ | ||
| Some XLForum reference threads:\\ | Some XLForum reference threads:\\ | ||
| - | http://xlforum.net/forums/showthread.php?t=254258\\ | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/53895-06-carb-to-07-fuel-injection-conversion?t=254258\\ |
| - | http://xlforum.net/forums/showthread.php?t=79795\\ | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal?t=79795\\ |
| - | http://xlforum.net/forums/showthread.php?t=1560232 (pics of '04 & '06 primary cover)\\ | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/143966-04-primary-cover-on-an-07?t=1560232 (pics of '04 & '06 primary cover)\\ |
| - | http://xlforum.net/forums/showthread.php?t=548729\\ | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/76901-primary-cover-differences-05-vs-06?t=548729\\ |
| - | http://xlforum.net/forums/showthread.php?t=1218730\\ | + | https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/123027-06-1200c-primary-oil-leak?t=1218730\\ |
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| | |--Steel 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)| | |Clutch pack service wear limit|0.6610 in. min. / (16.787 mm)| | ||
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| ===== Primary Drive (engine to transmission) ===== | ===== Primary Drive (engine to transmission) ===== | ||
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| |2004|9.647|6.633|5.143|4.248|3.643^ |9.004|6.190|4.800|3.965|3.400| | |2004|9.647|6.633|5.143|4.248|3.643^ |9.004|6.190|4.800|3.965|3.400| | ||
| + | ===== Mainshaft Fifth Gear ===== | ||
| - | ===== Mainshaft Fifth Gear Ball Bearing ===== | + | **L1994-2005 Mainshaft 5th Gear, Bearing & Spacer** |
| + | * 35034-94 - Gear Includes Needle Bearings | ||
| + | * 8996A - Ball Bearing | ||
| + | * 33344-94 - Drive Sprocket Spacer | ||
| - | 1991-2005 Mainshaft 5th Gear Bearing - Used on All Models ((04-05 HD Sportster Parts Catalogs)) | + | **2006-Later Mainshaft 5th Gear, Bearing & Spacer** |
| - | * 8996A - Ball Bearing | + | (Used on All Models except XR-1200 / XR1200X) |
| - | * 33344-85 - Drive Sprocket Spacer (1991-E1994) | + | * 35159-06 - Gear includes Needle Bearings |
| - | * 33344-94 - Drive Sprocket Spacer (L1994-2005) | + | * 35051-89A - Needle Bearings (2req) |
| - | + | * 8964 - Ball Bearing w/Built-in Drive Sprocket Spacer | |
| - | 2006 and later Mainshaft 5th Gear Bearing - Used on All Models (except XR-1200 / XR1200X) ((06 and up HD Sportster Parts Catalogs)) | + | |
| - | * 8964 - Ball Bearing w/Built-in Drive Sprocket Spacer | + | |
| Mainshaft 5th Gear Bearing - Used on XR-1200 and XR1200 Models ((09 and up HD Sportster Parts Catalogs)) | Mainshaft 5th Gear Bearing - Used on XR-1200 and XR1200 Models ((09 and up HD Sportster Parts Catalogs)) | ||
| Line 116: | Line 122: | ||
| * 33354-08 - Spacer | * 33354-08 - Spacer | ||
| + | \\ | ||
| {{:techtalk:evo:transfinal:mainshaft-5thgear-compare-1994-2006.jpg?600|}} | {{:techtalk:evo:transfinal:mainshaft-5thgear-compare-1994-2006.jpg?600|}} | ||
| \\ | \\ | ||
| + | |||
| ===== Final Drive (Trans to Rear Wheel) ===== | ===== Final Drive (Trans to Rear Wheel) ===== | ||
