Differences

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--- techtalk:ih:transfinal02 [2018/02/18 04:01]
hippysmack [Countershaft and Gears]
+++ techtalk:ih:transfinal02 [2024/01/02 03:41] (current)
hippysmack
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== IH: Transmission & Final Drive ======
-^Click here for tips on [[techtalk:ref:notes05#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^
+^Click here for tips on [[techtalk:ref:svcproc10#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^
 ====== 1957 - 1970 Sportster Four-Speed Constant Mesh Dry Clutch Transmission Specifications ======
@@ Line 8: / Line 8: @@
 ===== Sub-Documents =====
 * . . . [[techtalk:ih:transfinal02a|How to Adjust a Dry Clutch]] \\
-----
   * Type:
     * Dry - Multiple disc
+      * Worth noting is the MoCo had an optional wet clutch kit for 1954-up KH, XL, XLH, XLCH models. Kit # (37984-57) ((1959-1969 Sportster Parts Catalog Supplement 99451-69))
     * 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
@@ Line 34: / Line 29: @@
   * 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.
@@ Line 60: / Line 51: @@
   * 1967-1970 XLH (37700-67) ((HD Sportster Parts catalog 99451-78B))
   * 1970 XLCH (37701-70)((HD Sportster Parts catalog 99451-78B))
 **Primary Chain**
@@ Line 72: / Line 61: @@
   * 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 =====
@@ Line 79: / Line 67: @@
   * 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 =====
@@ Line 89: / Line 78: @@
 **Transmission Oil Capacity** ((1959-1969 HD Sportster FSM pg 1A-3)) ((1970-1978 HD Sportster FSM pg 1-1)): **1.5 pints / (24 oz) / (710 ml)**
 ===== Final Drive (Trans to Wheel) =====
 |Standard Year Model ((HD Spare Parts Catalog for all Sportster and K Models pg 30)) ((1953-1963 HD Sportster and KH Models Parts Catalog pg 38)) ((1961-1971 HD Sportster Parts Catalog pg 41)) ((1954-1976 HD Sportster Parts Catalog g 57)) ((1954-1978 HD Sportster Parts Catalog pg 75)) ((1979-1985 HD Sportster Parts Catalog pg 61)) ((1986-1990 HD Sportster Parts Catalog pg 45))|Part #|Transmission Sprocket:  \\ (All with a 51 Tooth Rear Wheel Sprocket)|
@@ Line 102: / Line 89: @@
 ^XLH^ ^^
 |1958 - E1967|35205-52A|21 Tooth|
-|L1967-1973|35198-52|20 Tooth ((1970-1978 Sportster FSM pg 1-1))|
+|L1967-1973|35198-52|20 Tooth ((1959-1969 HD Sportster / KH Parts Catalog Supplement)) ((1970-1978 Sportster FSM pg 1-1))|
 |1973-E1979|35205-52A|21 Tooth ((1970-1978 Sportster FSM pg 1-1))|
 ^XLCH^ ^^
 |1958|35205-52A|21 Tooth|
 |1959-E1969 XLCH|35198-52|20 Teeth|
-|L1969-1971 ((1970-1978 Sportster FSM pg 1-1)) \\ (Engine # 69XLCH 5921 →) ((HD Service Bulletin #455 dated 12-6-1961))|35197-52|19 Tooth|
+|L1969-1971 ((1970-1978 Sportster FSM pg 1-1)) \\ (Engine # 69XLCH 5921 →) ((TSB #582 dated 12-17-1968))|35197-52|19 Tooth|
 |1972-1973|35198-52|20 Tooth ((1970-1978 Sportster FSM pg 1-1))|
 |1973-E1979 ((1970-1978 Sportster FSM pg 1-1)) ((1954-1978 HD Sportster Parts Catalog pg 75)) ((1979-1985 HD Sportster Parts Catalog pg 61))|35205-52A ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Tooth ((1970-1978 Sportster FSM pg 1-1))|
@@ Line 114: / Line 101: @@
 |L1979-E1984|35208-79A|21 Tooth|
 |L1984-1990|35208-84|21 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 ((The Doctor71 of the XLFORUM)). Maybe a mid year change?
-----
 ===== Torque Specs =====
 |Clutch Hub Nut|150 ft lbs|
 ===== Mainshaft Group =====
   *Clutch gear ball bearing in case: .0001 - .0012 in loose
@@ Line 130: / Line 113: @@
   *Clutch gear on mainshaft: .001 - .002 in. loose
   *Mainshaft right side roller bearing: .0006 - .0014 in. loose
+  * Mainshaft roller bearings: ((dims provided by Gearhead88 of the XLFORUM https://www.xlforum.net/forum/forum-functions/sportsterpedia-com-admin/191119-send-a-note-to-sportsterpedia-admin/page12#post4620736))
+    * (9095) Standard = .1562"
+    * (9096) + .0004" = .1566"
+    * (9097) + .0008" = .1570"
   *Mainshaft end play: .004 - .009 in.
   *(1970) .003 - .009 in. with all axial play removed
@@ Line 136: / Line 123: @@
     * 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** ((HD Spare Parts Catalog for all Sportster and K Models 1952-1959 pg 31)) |||
@@ Line 159: / Line 142: @@
 |:::|Drive Sprocket 20T ((1954-1976 HD Sportster Parts Catalog pg 57)) \\  XLH/XLCH|35198-52|
 |:::|Drive Sprocket 19T ((1954-1976 HD Sportster Parts Catalog pg 57)) \\ XLH/XLCH|35197-52|
 ==== Mainshaft and Gears ====
@@ Line 166: / Line 148: @@
 |**L1956 KH** (engine # 1465 →) \\ **1957-1966 XL/XLH/XLCH** \\ **1967-1969 XLCH**|35044-56|1957|  |
 |**1967-1970 XLH** \\ **1970 XLCH**|35046-67|1967 \\ 1970|
-|**1971-1975 XLH/XLCH**|35046-71|1971|  |
-|**1971-1983 XLH/XLCH/XLS/XLX**|35046-71A|1976|  |
-|**L1984-1985 XLH/XLS/XLX**|35036-84A|L1984|  |
 ^Mainshaft Low Gear^^Change Year^Notes^
-|**1956 KH** \\ **1957-1985 XL/XLH/XLCH/XLS/XLX**|35277-52A (27T)|1957|  |
+|**1956 KH** \\ **1957-1985** \\ **XL/XLH/XLCH/XLS/XLX**|35277-52A (27T)|1957|  |
 ^Mainshaft 2nd Gear^^Change Year^Notes^
-|**1956 KH** \\ **1957-1965 XL/XLH/XLCH**|35269-56 (23T)|1957|  |
+|**1956 KH** \\ **1957-1965** \\ **XL/XLH/XLCH**|35269-56 (23T)|1957|  |
-|**1956 KH** \\ **1957-1983 XL/XLH/XLCH/XLS**|35296-56 (23T)|1966|  |
+|**1956 KH** \\ **1957-1985** \\ **XL/XLH/XLCH/XLS**|35296-56 (23T)|1966|O.D. - 2.648"-2.657" ((HD Service Bulletin #M906 dated August 19,1985))  |
-|**1979-1985 XLH/XLCH/XLS/XLX**|35296-56A (23T)|1985|  |
+|**1957-1986** \\ **XL/XLH/XLCH/XLS/XLX**|35296-56A (23T)|Early 1986|O.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. ((HD Service Bulletin #M906 dated August 19,1985)) |
 ^Mainshaft 3rd Gear^^Change Year^Notes^
-|**1956 KH** \\ **1957-1983 XL/XLH/XLCH/XLS**|35305-56 (20T)|1957|  |
+|**1956 KH** \\ **1957-1985** \\ **XL/XLH/XLCH/XLS**|35305-56 (20T)|1957|O.D. - 2.448"-2.452". ((HD Service Bulletin #M906 dated August 19,1985)) |
-|**1979-1985 XLH/XLCH/XLS/XLX**|35305-56A (20T)|1957|  |
+|**1957-1986** \\ **XL/XLH/XLCH/XLS/XLX**|35305-56A (20T)|Early 1986|O.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. ((HD Service Bulletin #M906 dated August 19,1985)) |
+=== Mainshaft roller bearings ===
+Standard rollers should measure .15625"-.15610". ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/147386-main-shaft-needle-bearing/page2?t=1601769&page=2)) \\
+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 ((photo by lynx of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/194680-1960-xlch-in-the-uk/page10?t=2070971&highlight=oil+filter&page=10))  |
+|{{:techtalk:ih:transfinal:1960_mainshaft_roller_bearings_by_lynnx.jpg?direct&400|}}|
 ===== Countershaft Group =====
@@ Line 207: / Line 198: @@
 |**1954-1956 KH** \\ **1957 XL**|35613-54|[[techtalk:ih:transfinal03#countershaft_and_oiler_plug|More information about countershafts and the oiler plug]]||
 |**1958-E1984** \\ **All**|35613-58|:::||
-|**L1984-1990** \\ **All**|35613-84|:::||
 ^Countershaft Drive Gear^Part No.^Change Year^Notes^
 |**1952-1956 K** (all) \\ **1957 XL**|35695-52 (29T)|-|
@@ Line 216: / Line 206: @@
 |**1954-1956 KH** \\ **1957 XL** \\ (replacement part)|35750-54C (21T)|1957|
 |**1958-1985** \\ **XL/XLC/XLH/XLCH/XLS**|35750-58 (20T)|1958|O.D. - 2.448"-2.452" ((HD Service Bulletin #M906 dated August 19,1985))|
-|**1957-1986** \\ **XL/XLC/XLH/XLCH/XLS/XLX** \\ (replacement part)|35750-58A (20T)|1986|O.D. - 2.423"-2.428". This was a running change in 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. ((HD Service Bulletin #M906 dated August 19,1985))|
+|**1957-1986** \\ **XL/XLC/XLH/XLCH/XLS/XLX** \\ (replacement part)|35750-58A (20T)|Early 1986|O.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. ((HD Service Bulletin #M906 dated August 19,1985))|
 ^Countershaft 3rd Gear^Part No.^Change Year^Notes^
 |**1954-1956 KH**|35709-54 (24T) ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25))|-|
 |**1954-1956 KH** \\ **1957-1985 XL/XLC/XLH/XLCH/XLS** \\ (replacement part)|35709-54A (23T)| 1957|O.D. - 2.648"-2.657" ((HD Service Bulletin #M906 dated August 19,1985))|
-|**1957-1986** \\ **XL/XLC/XLH/XLCH/XLS/XLX** \\ (replacement part)|35709-54B (23T)| 1986|O.D. - 2.622"-2.627". This was a running change in 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. ((HD Service Bulletin #M906 dated August 19,1985)) |
+|**1957-1986** \\ **XL/XLC/XLH/XLCH/XLS/XLX** \\ (replacement part)|35709-54B (23T)|Early 1986|O.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. ((HD Service Bulletin #M906 dated August 19,1985)) |
 ^Countershaft Low Gear^Part No.^Change Year^Notes^
 |**1954-1956 KH**|35759-54 (17T)|-|
@@ Line 226: / Line 216: @@
 |**1957-1971** \\ **XL/XLC/XLH/XLCH** \\ (replacement part)|35760-54A (17T)|Late 1966|Replaced 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)|
-|**1973-E1984 XLH/XLCH/XLS/XLX**|35760-73 (17T)|1973|  |
-|**L1984-1985 XLH/XLS/XLX**|35760-84A (17T)|L1984|  |
 \\
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