Table of Contents
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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 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
| Year | Overall Gear Ratios8) | Overall Gear Ratios9) | |||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| US Models 883 | US Models 1200 | ||||||||||
| 1st | 2nd | 3rd | 4th | 5th | 1st | 2nd | 3rd | 4th | 5th | ||
| 2004 | 10.944 | 7.524 | 5.834 | 4.806 | 4.071 | 9.454 | 6.500 | 5.040 | 4.152 | 3.517 | |
| Year | Overall Gear Ratios10) | Overall Gear Ratios11) | |||||||||
| HDI Models 883 | HDI Models 1200 | ||||||||||
| 1st | 2nd | 3rd | 4th | 5th | 1st | 2nd | 3rd | 4th | 5th | ||
| 2004 | 9.792 | 6.732 | 5.220 | 4.301 | 3.643 | 9.139 | 6.283 | 4.872 | 4.014 | 3.400 | |
| Year | Overall Gear Ratios12) | Overall Gear Ratios13) | |||||||||
| Japan Models 883 | Japan Models 1200 | ||||||||||
| 1st | 2nd | 3rd | 4th | 5th | 1st | 2nd | 3rd | 4th | 5th | ||
| 2004 | 9.647 | 6.633 | 5.143 | 4.248 | 3.643 | 9.004 | 6.190 | 4.800 | 3.965 | 3.400 | |
Final Drive (Trans to Rear Wheel)
| Year | Domestic Model(s) | Transmission Sprocket | Rear Wheel Sprocket | Secondary Drive Belt | Ratio |
|---|---|---|---|---|---|
| 2004 | 883/ 883C | 28 Teeth | 68 Teeth | 136 Teeth | 2.429:1 |
| 1200/ 1200R | 29 Teeth | 68 Teeth | 137 Teeth | 2.345:1 | |
| Year | HDI / Japan Model(s) | Transmission Sprocket | Rear Wheel Sprocket | Secondary Drive Belt | Ratio |
| 2004 | 883 / 883C | 28 Teeth | 68 Teeth | 136 Teeth | 2.429:1 |
| 1200 / 1200R | 30 Teeth | 68 Teeth | 137 Teeth | 2.267:1 |
2)
oo_buck_us in Post#15 - http://xlforum.net/forums/showthread.php?t=1560232
3)
2004 HD FSM pg 6-2
