IH: Transmission & Final Drive

1957 - 1970 Sportster Four-Speed Constant Mesh Dry Clutch Transmission Specifications

Clutch

Sub-Documents

* . . . How to Adjust a Dry Clutch


  • Type:
    • Dry - Multiple disc
    • 7 friction plates, 7 steel plates between a steel backing plate and a front releasing disc
    • Back to front: Backing plate-S-F-S-F-S-F-S-F-S-F-S-F-S-F-Releasing disc
  • Capacity: 1900 in-lbs. (158.33 ft lbs.)
  • Set up Spring Pressure: 150 lbs.
    • Spring adjustment: 3/16 in. from inner surface of spring tension adjusting plate to outer surface of spring cup flange
  • Clutch bearing: .0005 - .002 in. loose
  • (1970) - .0005 - .0029 in. loose
  • Clutch cover: Must be leak proof. No gasket sealer
  • Clutch release rod movement: .095 - .115 in.

Adjusting Clutch Release Mechanism

  • Loosen clutch release rod adjusting screw lock nut and rod adjusting screw. Clutch release worm (inside the sprocket cover) should seat against it's stop when clutch handle is fully extended. If lever doesn't fully seat, check for cable binding in housing.
  • Adjust cable length by turning the adjusting sleeve (at hand lever) so the clutch release worm does not quite return against it's stop. This will hold the hand lever in it's fully extended position at all times.
  • Tighten clutch release rod adjusting screw until hand lever has 1/8 in. free play before clutch starts to release (slight tension).
  • Tighten locknut without disturbing the current cable setting.

Shifter Cam Assembly

  • Shifting problems after considerable mileage could be caused by a loose shifter cam assembly which results in trouble shifting the lever into various gears. It can also cause the transmission to suddenly drop out of gear.
  • The shifter cam assembly is secured to the access cover with a bolt (7/16”x14x1-1/8”), a lockwasher and 2 dowel pins registering in the access cover. If the assembly becomes loose, the (press fitted) dowel pins can work loose from the assembly and into the access cover holes. When the dowel pins have successfully worked their way out of the assembly support, the shifter cam will tip causing a bind in the mechanism. 1)
  • If you’re having shifting problems and you’re sure it’s not because of a dragging clutch (before doing exploratory surgery on the internal tranny parts), try removing the chain cover and check for a loose shift assembly bolt. The bolt may appear tight, but it has been known to bottom out in the hole from being slightly too long which allows it to get tight before full clamping force on the assembly. 2)
  • To properly tighten up the assembly, you can remove the clutch and access cover to check and make sure the dowel pins are properly press fit into the support holes and are a snug fit into the access cover. If the dowels are loose in the cover holes (slight wear), try replacing the standard dowel pins (9220A) with an oversized pair (+0.001 - 9225A), (+0.002 - 9227A) or (+0.003 - 9229A). 3) If the holes are out of round in the access door, the door may have to be replaced. A good machinist could probably re-drill the holes straight to accept bigger pins also. 4)
  • When re-assembling the shifter assembly to the access cover, be sure the bolt and lockwasher secure it tight to the door. If necessary, you can shorten the bolt by 1/16” (or one thread) with a Dremil tool with a metal cutting blade or a hacksaw. If the bolt still bottoms out, the threaded hole is too shallow and the pawl carrier support (34514-52) may have to be replaced. 5)
  • Click here for pics and identification of shifter assemblies: Pics of Pawl Carriers and Pawl Carrier Supports

Primary Drive (engine to transmission)

Year Model(s)Engine SprocketClutch Sprocket
Standard1966 & Earlier XLCH
1967 & later XLH, XLCH
34 Teeth59 Teeth
Optional1966 and Earlier XL, XLH
1967 XLH, XLCH
34 Teeth59 Teeth

Clutch Sprocket Assembly

  • Late 1957-1966 XL, XLH, XLCH (37702-57) 6)
  • 1967-1969 XLCH (37702-57) 7)
  • 1967-1970 XLH (37700-67) 8)
  • 1970 XLCH (37701-70)9)

Primary Chain

  • Type primary: 3/8 in. pitch triple chain
  • Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine)

Kick Starter

The kick starter provides a means of starting the engine by manual power. When the pedal is moved in a downward stroke, ratchet teeth of the starter clutch gear and the starter clutch are engaged, transmitting force to the clutch sprocket, primary drive chain and to the engine sprocket.

  • Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in.
  • Crankshaft endplay: .001 - .007 in.

Electric Start

On 1967 and later model XLH, an electric starter motor and Bendix type drive unit engage the ring gear on the clutch to crank the engine.

Gear Shifter

  • The shifter is located on the right side of the engine and is foot operated transmitting force through the gear shift shaft, actuating pawl carrier, pawls and gear shifter cam.
  • The shifter cam moves shifter forks which slide a series of gear clutches on the mainshaft and countershaft into mesh with the various gears to obtain the desired ratios.

Transmission

  • Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution.
Overall Gear Ratios
Year Models1st2nd3rd4th
Standard1966 & Earlier XLCH
1967 & Later XLH, XLCH
11.16:18.08:16.11:14.42:1
Optional1966 & Earlier XL, XLH
1967 XLH, XLCH
10.63:17.69:15.82:14.21:1

Transmission Oil Capacity 10) 11): 1.5 pints / (24 oz) / (710 ml)

Final Drive (Trans to Wheel)

Standard Year Model 12) 13) 14) 15) 16) 17) 18)Part #Transmission Sprocket:
(All with a 51 Tooth Rear Wheel Sprocket)
XL
E195735205-5221 Tooth
L1957-195935205-52A
XLC
195835205-52A21 Tooth
XLH
1958 - E196735205-52A21 Tooth
L1967-197335198-5220 Tooth 19)
1973-E197935205-52A21 Tooth 20)
XLCH
195835205-52A21 Tooth
1959-E1969 XLCH35198-5220 Teeth
L1969-1971 21)
(Engine # 69XLCH 5921 →) 22)
35197-5219 Tooth
1972-197335198-5220 Tooth 23)
1973-E1979 24) 25) 26)35205-52A 27)21 Tooth 28)
L197935208-79A21 Tooth
XL/XLS/XLX
L1979-E198435208-79A21 Tooth
L1984-199035208-8421 Tooth
  • By the time the 1976 parts catalog came out, all three early transmission sprocket versions were available for replacement of the original no matter which bike you had and from 1954 to then current. It stayed that way until Late 1979 in the parts catalogs. However, 1973 and up Sportsters all came factory with a 21T sprocket, according to the FSM. There is also an overlap in 1973 in that the FSM(s) states a 21T and a 20T for 1973 29). Maybe a mid year change?

Torque Specs

Clutch Hub Nut150 ft lbs

Mainshaft Group

  • Clutch gear ball bearing in case: .0001 - .0012 in loose
  • Ball bearing on clutch gear: .0001 in. loose - .0009 in. tight
  • Clutch gear on mainshaft: .001 - .002 in. loose
  • Mainshaft right side roller bearing: .0006 - .0014 in. loose
  • Mainshaft end play: .004 - .009 in.
  • (1970) .003 - .009 in. with all axial play removed
  • Third gear
    • On shaft: .002 - .003 in. loose
    • End play: .015 - .025 in. loose
    • (1970) .012 - .030 in

Clutch Gear, Clutch Gear Washer, Needle Bearings & Bushing, Drive Sprocket

1956-1966 KH (engine #1465 →) XL/XLH/XLCH
1967-1969 XLCH 30)
Clutch Gear37450-56
replaced by
37449-56
Clutch Gear Washer35361-56
Needle Bearings (2)35960-54 (closed end)
replaced by
35961-52 (open end)
Clutch Gear Bushing37458-52
Drive Sprocket 21T 31)
1952-1953 K/KK
1954-1955 KH (engine #1689 →) 32)
1957-1959 XL
1958-E1967 XLH
1958-1971 XLCH (except 1959)
35205-52
replaced by
35205-52A
Drive Sprocket 20T 33) 34) 35) 36) 37)
1959-1971 XLCH
L1967-1971 XLH
35198-52
Drive Sprocket 19T 38) 39)
1953-1956 K/KH
L1969 XLCH (engine #69XLCH-5921 →)
35197-52
1967-1970 XLH
1970 XLCH
Clutch Gear37448-67
Clutch Gear Washer35361-56
Needle Bearings (2)35961-52
Clutch Gear Bushing37458-52
Drive Sprocket 21T 40)
XLH/XLCH
35205-52A
Drive Sprocket 20T 41)
XLH/XLCH
35198-52
Drive Sprocket 19T 42)
XLH/XLCH
35197-52

Mainshaft and Gears

MainshaftPart #Change YearNotes 43) 44) 45) 46) 47) 48) 49) 50) 51) 52) 53) 54) 55) 56) 57)
L1956 KH (engine # 1465 →)
1957-1966 XL/XLH/XLCH
1967-1969 XLCH
35044-561957
1967-1970 XLH
1970 XLCH
35046-671967
1970
Mainshaft Low GearChange YearNotes
1956 KH
1957-1985
XL/XLH/XLCH/XLS/XLX
35277-52A (27T)1957
Mainshaft 2nd GearChange YearNotes
1956 KH
1957-1965
XL/XLH/XLCH
35269-56 (23T)1957
1956 KH
1957-1985
XL/XLH/XLCH/XLS
35296-56 (23T)1966O.D. - 2.648“-2.657” 58)
1957-1986
XL/XLH/XLCH/XLS/XLX
35296-56A (23T)Early 1986O.D. - 2.622“-2.627”. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 59)
Mainshaft 3rd GearChange YearNotes
1956 KH
1957-1985
XL/XLH/XLCH/XLS
35305-56 (20T)1957O.D. - 2.448“-2.452”. 60)
1957-1986
XL/XLH/XLCH/XLS/XLX
35305-56A (20T)Early 1986O.D. - 2.423“-2.428”. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 61)

Mainshaft roller bearings

Standard rollers should measure .15625“-.15610”. 62)
Fit to shaft may not be determined by race size.
In order to fit 23 new std rollers in the race, it needs to be big enough to accept 23 rollers with out the rollers binding in the race.
When sized to the min. dia. that accepts 23 rollers with out bind, the shaft (.991“ dia) will be will be about .002 running clearance.
This is because there is no roller cage. The rollers touch each other.
Because of the zero% roller to roller space trying to fit 23 o.s. rollers means the race needs to a lot bigger than the roller amount of roller o.s.
This results in a looser running fit than used in the standard rollers.
To use the os rollers and get a tighter fit than 23 standards, you can only use 22 o.s rollers.
Rigid hone / line lap race to take 23 standards.
Then let clearance be whatever it is.

Mainshaft roller bearings 63)

Countershaft Group

  • Countershaft end bearings: Retained needle roller bearing
  • Bearing fit on shaft ends: .0005 - .002 in. loose
  • Bearing fit in case: press
  • End play: .004 - .009 in.
  • Second gear
    • On shaft: .001 - .0025 in. loose
  • Low gear
    • On shaft: .0005 - .0016 in. loose
    • End play: .004 - .009 in.
  • Drive gear
    • On shaft: .001 - .0025 in. loose
    • (1970) .0005 - .0030 in. loose
    • End play: .004 - .009 in.
  • Clearance between clutch faces
    • Countershaft low an third gear: .038 - .058 in.
    • Countershaft second and third gear: .038 - .058 in.
    • 1970
      • Mainshaft clutch gear and second gear: .043 - .083 in.
      • Mainshaft third gear and second gear: .043 - .083 in.
      • Shifter end play: .010 - .030 in

Countershaft and Gears

CountershaftPart No.Notes 64) 65) 66) 67) 68) 69) 70) 71) 72) 73) 74) 75) 76) 77)
1954-1956 KH
1957 XL
35613-54More information about countershafts and the oiler plug
1958-E1984
All
35613-58
Countershaft Drive GearPart No.Change YearNotes
1952-1956 K (all)
1957 XL
35695-52 (29T)-
1952-1956 K (all)
1957 XL
35695-52A (27T)-
1958-1985
XL/XLC/XLH/XLCH/XLS
35695-58 (27T)1958
Countershaft 2nd GearPart No.Change YearNotes
1954-1956 KH35750-54B (21T)-
1954-1956 KH
1957 XL
(replacement part)
35750-54C (21T)1957
1958-1985
XL/XLC/XLH/XLCH/XLS
35750-58 (20T)1958O.D. - 2.448”-2.452“ 78)
1957-1986
XL/XLC/XLH/XLCH/XLS/XLX
(replacement part)
35750-58A (20T)Early 1986O.D. - 2.423”-2.428“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 79)
Countershaft 3rd GearPart No.Change YearNotes
1954-1956 KH35709-54 (24T) 80)-
1954-1956 KH
1957-1985 XL/XLC/XLH/XLCH/XLS
(replacement part)
35709-54A (23T) 1957O.D. - 2.648”-2.657“ 81)
1957-1986
XL/XLC/XLH/XLCH/XLS/XLX
(replacement part)
35709-54B (23T)Early 1986O.D. - 2.622”-2.627“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 82)
Countershaft Low GearPart No.Change YearNotes
1954-1956 KH35759-54 (17T)-
1957-Early 1966
XL/XLC/XLH/XLCH
35760-54 (17T)1957Single counter-bore (case side) allowing gear to slip over the right case casting boss.
Cannot be used on Late '66 and later right case with added fillet at the base of the gear boss.
1957-1971
XL/XLC/XLH/XLCH
(replacement part)
35760-54A (17T)Late 1966Replaced 35760-54 with an added counter-bore on case side to clear the added fillet in the new cases.
1957-1972
XL/XLH/XLCH
(replacement part)
35760-54B (17T)1972(with speedometer drive gear)


1) , 2) , 3) , 4) , 5)
HD Service Bulletin #541 dated July 15, 1966 pg OC-225
6) , 7) , 8) , 9)
HD Sportster Parts catalog 99451-78B
10)
1959-1969 HD Sportster FSM pg 1A-3
11)
1970-1978 HD Sportster FSM pg 1-1
12) , 32)
HD Spare Parts Catalog for all Sportster and K Models pg 30
13)
1953-1963 HD Sportster and KH Models Parts Catalog pg 38
14) , 37) , 39)
1961-1971 HD Sportster Parts Catalog pg 41
15)
1954-1976 HD Sportster Parts Catalog g 57
16) , 25)
1954-1978 HD Sportster Parts Catalog pg 75
17) , 26) , 27)
1979-1985 HD Sportster Parts Catalog pg 61
18)
1986-1990 HD Sportster Parts Catalog pg 45
19) , 20) , 21) , 23) , 24) , 28)
1970-1978 Sportster FSM pg 1-1
22)
HD Service Bulletin #455 dated 12-6-1961
29)
The Doctor71 of the XLFORUM
30)
HD Spare Parts Catalog for all Sportster and K Models 1952-1959 pg 31
31) , 33)
1957-1967 HD Sportster and KH Model Parts Catalog pg 39
34)
1959-1969 Sportster and KH Model Parts Catalog
35)
1952-1959 HD Spare Parts Catalog pg 35
36) , 38)
1953-1963 HD Parts Catalog for Sportsters and K Models pg 38
40) , 41) , 42)
1954-1976 HD Sportster Parts Catalog pg 57
43) , 64) , 80)
1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25
44) , 66)
1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30
45)
1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 33
46) , 68)
1955-1965 Sportster/KH Model Parts Catalog pg 34
47)
1966 Sportster/KH Model Parts Catalog Supplement
48)
1957-1967 Sportster/KH Model Parts Catalog pg 33
49)
1961-1971 HD Sportster Parts Catalog pg 33,34
50)
1962-1976 HD Sportster Parts Catalog Supplement
51) , 72)
1979 HD Sportster Parts Catalog pg 30,31
52)
1979-1980 HD Sportster Parts Catalog pg 30,31
53)
1979-1981 HD Sportster Parts Catalog pg 39
54)
1979-1981 HD Sportster Parts Catalog pg 39,41
55)
1979-1982 HD Sportster Parts Catalog pg 43
56)
1979-1983 HD Sportster Parts Catalog pg 43,45
57)
1979-1985 HD Sportster Parts Catalog pg 49
58) , 59) , 60) , 61) , 78) , 79) , 81) , 82)
HD Service Bulletin #M906 dated August 19,1985
65)
1958 HD Supplement Spare Parts Catalog for Sportster and K Models pg 25
67)
1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 34
69)
HD Service Bulletin #537 dated March 22, 1866 pg OC-221
70)
1957-1967 HD Sportster/KH Model Parts Catalog pg 34
71)
1961-1971 HD Sportster Parts Catalog pg 34
73)
1979-1980 HD Sportster Parts Catalog pg 31
74)
1979-1981 HD Sportster Parts Catalog pg 41
75)
1979-1982 HD Sportster Parts Catalog pg 44
76)
1979-1983 HD Sportster Parts Catalog pg 45
77)
1979-1985 HD Sportster Parts Catalog pg 51
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