Table of Contents
This is an old revision of the document!
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
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 | |
Shaft Bushing+ | 40520-63 | 40574-06A | |
Shaft Oil Seal+ | 11000101++ | 37107-06 | |
Shaft Washer | 7019 | 7019 | 7080 |
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+) |
|
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. 2)
++_latest P/N (orig P/N 37101-84)
NOTE: Some have gotten 2006-later covers by mistake 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, fits like a glove.3)
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
(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.
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.
Some XLForum reference threads:
http://xlforum.net/forums/showthread.php?t=254258
http://xlforum.net/forums/showthread.php?t=79795
http://xlforum.net/forums/showthread.php?t=1560232 (pics of '04 & '06 primary cover)
http://xlforum.net/forums/showthread.php?t=548729
http://xlforum.net/forums/showthread.php?t=1218730
Clutch
2004 Wet Clutch Information 5) | ||
---|---|---|
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 Ratios10) | Overall Gear Ratios11) | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|
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 Ratios12) | Overall Gear Ratios13) | |||||||||
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 Ratios14) | Overall Gear Ratios15) | |||||||||
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 |
Mainshaft Fifth Gear
L1994-2005 Mainshaft 5th Gear, Bearing & Spacer
- 35034-94 - Gear Includes Needle Bearings
- 8996A - Ball Bearing
- 33344-94 - Drive Sprocket Spacer
2006-Later Mainshaft 5th Gear, Bearing & Spacer (Used on All Models except XR-1200 / XR1200X)
- 35159-06 - Gear includes Needle Bearings
- 35051-89A - Needle Bearings (2req)
- 8964 - Ball Bearing w/Built-in Drive Sprocket Spacer
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)
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 |