IH: Transmission & Final Drive

1971 - 1985 Sportster Four-Speed Constant Mesh Wet Clutch Transmission & Specifications

Transmission Changes by Year

Transmission Changes in 1979

* Changes were made in early 1979 production engines to improve the engagement of the clutch teeth between the mainshaft 2nd gear and the clutch gear. 1)

  • On September 21, 1978 starting with crank­ case (# 779-26 4- 021), the mainshaft clutch gear thrust washer thickness was decreased .020“ from .232” to .212“ (nominal). The transmission drive sprocket hub width was increased .020” to compensate for the clutch gear change. 2)
  • This upgrade was recommended as a replacement for earlier transmissions, especially those with severe shifting service where rounding of the gear teeth is likely to occur. 3)
  • A new drive sprocket (35205-79) must be used in conjunction with the new clutch gear, (with the new thinner thrust washer), to retain the proper drive sprocket position. Either install a new washer (35216-79) in the old clutch gear (37448-71) or use a new clutch gear (37448-79) which comes with the new washer already installed. 4)
  • To convert an old clutch gear to this new one: 5)
  • Remove the thrust washer and needle bearing using a puller, with a 3/4“ collet, pressing out with a rod inserted from the opposite end of gear. If you can't get your hands on the tool, these parts can also be drifted with a hammer and punch, (Caution should be used since this method can damage the bushing). 6)
  • Press in new needle bearing (35961-52) and new thrust washer (35216-79). When pressing in needle bearing, press on the printed side of the bearing cage. The outer face of the bearing cage should be flush with the washer seating face (do not bottom out the bearing in the hole when pressing it in).
  • After assembling sprocket on mainshaft, be sure to check mainshaft endplay with pre-load (.003” - .009“). Adjust if necessary using variable thickness mainshaft thrust washer in accordance with the FSM.

Transmission Access Cover (Trapdoor)

Oil Transfer Hole

  • During the 1975 season, the MoCo received several reports of XL & XLCH transmissions with a blocked oil transfer hole in the trapdoor (resulting in little to no oil supply to the transmission). So, they recommended that the dealers remove the transmission oil drain plug & measure how much oil dropped out. If less than 1.5 pints of oil ran out, the transfer hole was to be checked for blockage. This can be remedied by tapping the casting with a hammer and a punch at the hole location (1/2” hole directly below the countershaft hole). Done carefully to prevent chips from getting into the transmission, loose chips may still fall into the hole which will require flushing out the drain hole. 7)

Trapdoor Changes

L1984 trapdoor (34847-84)

Used after July 26, 1984 beginning with crankcase #785 208001, will retrofit to all XL models with an alternator and utilizes two slots for removal. An alignment tool (SNAP-ON 1650) or (MAC LF-12) or equivalent in the shape of a crowbar is recommended by the MoCo to draw the access door from the dowel pins. You can use a propane torch to carefully apply heat to the access door dowel pin area. Do not allow flame to rest on any one area for a prolonged period of time and wipe all the oil from access door prior to heating. Insert the hook end into each slot and gently alternate between the slots to evenly remove the door from the dowel pins. 8) It was sold for parts order as a kit including a retaining ring (11006) for the mainshaft / fourth gear bearing assembly and four T-27 screws (2712). 9) The torx screws contained a thread locker in pellet form on the threads which, when the screw is started in the hole, breaks and releases the compound. As a result, the old screws could not be used. The stator is directly bolted to the door by the four torx locking screws at 30-40 in-lbs. The L84-85 stator (29966-84) 10) has 8 mounting holes with only four being used. To prevent possible chafing of the stator wire, you must use the proper holes when mounting the stator. Starting with the upper right set of holes (1-2) and numbering clockwise from 1-8, you must use holes number 1, 3, 6 & 7. The 85 stator (29967-84) 11) only has 4 holes. The mainshaft fourth gear bearing rests against a shelf in the trapdoor bore while the retaining ring sits in a groove in the door behind the bearing locking it in place. This beveled retaining ring is installed with the bevel side facing the transmission and the flat side facing the bearing.

Model YearsPart #Retrofit to Years
1957-197434844-57 - 12)
1975-197634844-57A1957-1976 13) 14)
1977-E197934844-57B - 15) 16)
L1979-E198434847-79 - 17)
L1984-198534847-84 - 18)

Click on a pic to enlarge:

1977 4 Speed Transmission 19) 1977 4 Speed Trap Door 20) 1983 4 Speed 21)
1978 4 Speed transmission 22)

Clutch

Sub-Documents

* . . . "The Harton Fix" - Late 84-90 clutch shell magnet fix



  • Type
    • Wet - Multiple disc
  • 1971-1978 23)
  • 8 Drive plates (37985-71), 8 Driven Plates (37992-71A), with an outer drive plate (37987-71) and retaining ring (11053).
  • Back to Front : Backing Plate-F-S-F-S-F-S-F-S-F-S-F-S-F-S-F-S-Outer Drive Plate with retaining ring.
  • Capacity: 1900 in-lbs (158.33 ft lbs.)
  • Set up Spring Pressure
    • 1971: 234 lbs. 24)
    • 1972: 257 lbs. 25)
  • Spring adjustment
    • 1971 - 1973: 11/32 in. from outer surface of outer drive plate to outer surface of releasing disc 26)
    • Late 1974 & later:
    • Clutch changes include a new pressure plate (38005-71B) and six spacers (5995) over the studs between the pressure plate and the releasing disc allowing the spring set-up pressure to be set at a controlled amount. A conversion kit (38005-71B), which contained the new pressure plate and spacers, was available to convert 71-E73 models to the new 74 style set-up. The stud holes in the clutch unlined plates (37992-71) were modified to fit loosely over six spacers. New plates have larger oblong holes and round stud holes. 27)
    • Standard Spacers: (5995) - 1.530“ long. 28)
      • Shorter spacers to increase the spring tension due to disc lining wear:
        • (5996) - 1.490” long. 29)
        • (5997) - 1.450“ long. 30)
          Note: The six spring tension nut adjusters (7686) and retainers (37499-71) are no longer used since the clutch spring set-up pressure is adjusted differently with this change. 31)
  • Clutch bearing: .0005 - .002 in. loose 32)
  • Periodic adjustment of the clutch is required every 2,000 miles to compensate for lining wear. 33)
  • Adjustment may also be necessary with the clutch slipping under load or dragging in the released position. 34)
  • 1979- Early 1984 35)
  • Capacity: 174 ft lbs.
  • Spring Adjustment- Fixed spacers standard length 1.530 in.
    • Free Length- inner- 2-25/64 in.
      • Wear limit: 2 - 11/32 in.
    • Free Length- outer- 2-25/64 in.
      • Wear limit: 2 - 11/32 in.
  • Clutch Shell Bearing on clutch gear: .0000 - .0010 in. loose
  • Clutch Plate max. warp-age: .010 in.
  • Late 1984-1985 36)
  • Capacity:174 ft lbs.
  • Spring Force (engaged): 304 lbs.
  • Spring Force (dis-engaged):260 lbs.
  • Clutch Shell Bearing on clutch gear: .0000 in. - .0010 in. loose

Adjusting Clutch Release Mechanism

Clutch adjustment is recommended every 2,000 miles to compensate for lining wear or during clutch slippage under load, or when clutch is dragging in released position. 37)

  • Loosen adjuster locknut at primary case and turn adjuster inward until there is a large amount of free play at hand lever. 38)
  • Remove access plug from primary cover to view adjusting screw. 39)
  • Loosen adjusting screw lock nut and turn adjusting screw inward until it becomes harder to turn (starts to release the clutch) and continue turning (app 2 more turns) to be sure clutch is dis-engaged. 40)
  • Adjust all free play out of control cable by turning adjuster outward. Do not put any tension on cable. With all slack in cable taken out (no play at hand lever) tighten the adjuster locknut. 41)
  • Ready for final clutch release adjustment: Loosen the locknut and back off the adjusting screw until the clutch is engaged (pressure is off the screw) then turn screw inward until the point of no free play. Then turn the adjusting screw outward 1/4 - 1/2 turn to establish the correct amount of free play and tighten the lock nut. Check free play at hand lever. you should have 1/8 in. free play. If not, adjust sleeve and tighten lock nut. 42)
  • If clutch slips or drags after these adjustments, it may be necessary to inspect / adjust the clutch springs and / or clutch release mechanism for defects. 43)

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, 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. 44)
  • 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. 45)
  • 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 with an oversized pair (+0.001), (+0.002) or (+0.003). 46) 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. 47)
  • 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 may have to be replaced. 48)
  • 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
1971-1978 all models 49) 34 Teeth59 Teeth

Clutch Sprocket Assembly

1971-1978 XLH
1979 XL
1979-1980 XLS
(37716-71A) 50)51)
1971-1978 XLCH
1979 XL, XLS
(37717-79) 52)53)
Early 1979 XLCH37701-71A 54)
1981-Early 1984 XL, XLS, XLX37716-81 55)
Late 1984-1985 all models
Clutch Shell & Sprocket
w starter gear
36791-84 56)

Primary Chain

  • Type primary: 3/8 in. pitch triple chain 57)
  • Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine) 58)

Kick Starter

On the XLCH, 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. 59)

  • Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in. 60)61)
  • Crankshaft endplay: .001 - .007 in. 62)63)
  • 1979 was the last year you can outfit a Sportster with a kickstarter 64)

Electric Start

On the XLH, an electric starter motor and Bendix type drive unit engage the ring gear on the clutch to crank the engine. 65)

Gear Shifter

1971-1974

  • 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. 66)
  • 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. 67)

1975-1976

  • To convert shifting from right side to left side, the shifter pedal was moved to the left side of the motorcycle and connected through a cross shaft linkage system to the shifter mechanism on the right side. 68)

1977-1985

  • The shifter shaft was redesigned again (34628-75) for 1977 and up models but still leaving it on the left side of the bike. 69) 70)
1977-1985 shift lever shaft 71)

Transmission

  • Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution. 72)
1971- 1985 model(s) Overall Gear Ratios
1st2nd3rd4th
1970-1971 XLCH73)11.748.506.434.66
1970-1973 XL, XLH
1972-1973 XLCH74)
11.168.086.114.42
1973-1981 all models75)76)10.637.705.824.22
1982- Early 1984 all models77)10.027.255.493.97
Late 1984-1985 all models78)10.017.255.493.97

Transmission/ Primary Oil Capacity 79) 80): 1.5 pints (24 oz) (710 ml)

Final Drive (Trans to Wheel)

Year Model(s)Transmission SprocketRear Wheel Sprocket
1970-1971 XLCH81)19 Teeth51 Teeth
1970-1973 XL, XLH82)
1972-1973 XLCH83)
20 Teeth51 Teeth
1973-1981 all models84)21 Teeth51 Teeth
Early 1979 XL, XLCH85)19 Teeth
20 Teeth
21 Teeth
51 Teeth
Late 1979-1981 XL, XLS, XLX 86)21 Teeth 51 Teeth
1982-1985 XL, XLS,XLX 87)21 Teeth48 teeth

1971-1985 Torque Specs

1979 - Late 1984 Torque Specs

Clutch Hub Nut88)110 - 150 ft lbs
Mainshaft Nut89)35 - 65 ft lbs
Access Cover Screws90)13 - 15 ft lbs
Drain Plug91)14 - 21 ft lbs
Primary Cover Screws92)80 - 110 in. lbs
Chain Tensioner Stud Nut93)8 - 12 ft lbs

Late 1984 - 1985 Torque Specs

Mainshaft Nut Locking Screw94)50 - 60 in. lbs
Mainshaft Nut95)35-65 ft lbs
Access Cover Screws96)13 - 15 ft lbs
Drain Plug97)14-21 ft lbs
Primary Cover Screws98)80 - 110 in. lbs
Chain Tensioner Stud Nut99)8 - 12 ft lbs
Stator Screws (4 slotted)100)20 - 35 in lbs
Stator Mounting (4 hex socket)101)20 - 35 in lbs
Stator Mounting Torx fasteners102)30 - 40 in. lbs

Mainshaft Group

  • 1971 - 1978 103)
  • 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: .003 - .009 in. with all axial play removed
  • Third gear
    • On shaft: .002 - .003 in. loose
    • End play: .012 - .030 in. loose
  • 1979 - Early 1984 104)
  • Clutch gear ball bearing in case: .0001 - .0012 in loose
  • Ball bearing on clutch gear: .0009 in. tight
  • Clutch gear on mainshaft: .001 - .002 in. loose
  • Mainshaft right side roller bearing: .001 - .0034 in. loose
  • Mainshaft end play:
    • No axial play (minimum)- .003 in.
    • With axial play - .020 in.
  • Clearance between clutch faces:
    • Mainshaft fourth gear and second gear: .028 - .058 in.
    • Mainshaft third gear and second gear: .028 - .058 in.
  • Late 1984 - 1985 105)
  • Clutch gear ball bearing in case: .0001 - .0012 in loose
  • Ball bearing on clutch gear: .0009 in. tight
  • Clutch gear on mainshaft: .001 - .002 in. loose
  • Mainshaft right side roller bearing: .001 - .0034 in. loose
  • Mainshaft end play:
  • Minimum - .009 in.
  • Maximum - .015 in.
  • Clearance between clutch faces:
  • Mainshaft fourth gear and second gear: .028 - .058 in.
  • Mainshaft third gear and second gear: .028 - .058 in.

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

1971-E1979 XLH/XLCH 106)107)
Clutch Gear 17T37448-71
replaced in E1979 by
37448-79
Clutch Gear Washer (.232”)35361-56
replaced in E1979 by
35216-79
(.020" thinner)
Needle Bearings (2)35961-52
Clutch Gear Bushing37458-52
Drive Sprocket 21T35205-52A
replaced in E1979 by
35205-79
( hub width was increased .020”)
Drive Sprocket 20T35198-52
Drive Sprocket 19T35197-52
L1979 XLCH
L1979-E1984 XLH/XLS 108) 109)
1983-1984 XLX 110)
Clutch Gear 17T37448-79
Clutch Gear Washer (.212“)35216-79
Needle Bearings (2)35961-52
Clutch Gear Bushing37458-52
Drive Sprocket 21T37448-79
Drive Sprocket 20T35198-52
Drive Sprocket 19T35197-52
L1984-1985 XL/XLS/XLX 111)
Clutch Gear 17T37448-84A
Clutch Gear Washer (.212”)35216-79
Needle Bearings (2)35961-52
Clutch Gear Bushing37458-52
Drive Sprocket 21T35208-84
Drive Sprocket 20T35198-52
Drive Sprocket 19T35197-52

Transmission Mainshaft Shims

1979 and Earlier.
By October of 1982, the number of mainshaft (R) shims for parts order increased to a total of
10 sizes. These parts will retrofit Sportster transmissions back to 1954 K Models 112)
Thrust Washer (Right)Size Thrust Washer (Right)Size
35343-73.030“ 35352-520.65”
35344-73.040“ 35353-520.70”
35349-52.050“ 35354-520.75”
35350-52.055“ 35326-730.80”
35351-52.060“ 35355-720.85”

Mainshaft and Gears

MainshaftPart #Change YearNotes 113) 114) 115) 116) 117) 118) 119) 120) 121) 122) 123) 124) 125) 126) 127)
1971-1975 XLH/XLCH35046-711971
1971-1983
XLH/XLCH/XLS/XLX
35046-71A1976
L1984-1985 XLH/XLS/XLX35036-84AL1984
Mainshaft Low GearChange YearNotes
1956 KH
1957-1985
XL/XLH/XLCH/XLS/XLX
35277-52A (27T)1957
Mainshaft 2nd GearChange YearNotes
1956 KH
1957-1985
XL/XLH/XLCH/XLS
35296-56 (23T)1966O.D. - 2.648“-2.657” 128)
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. 129)
Mainshaft 3rd GearChange YearNotes
1956 KH
1957-1985
XL/XLH/XLCH/XLS
35305-56 (20T)1957O.D. - 2.448“-2.452”. 130)
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. 131)

Countershaft Group

  • 1971 - Early 1978 132)
  • Countershaft end bearings: Retained needle roller bearing
  • Bearing fit on shaft ends: .0005 - .0029 in. loose
  • Bearing fit in case: press fit
    • 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. (1971-1978)
  • Drive gear
    • On shaft: .0005 - .0030 in. loose
    • End play: .004 - .009 in. (1971-1978)
  • Clearance between clutch faces
    • Countershaft low an third gear: .038 - .058 in.
    • Countershaft second and third gear: .038 - .058 in.
    • Mainshaft clutch gear and second gear: .043 - .083 in.
    • Mainshaft third gear and second gear: .043 - .083 in.
  • Shifter end play (1971-1976): .010 - .030 in.
  • 1979-Early 1984 133)
  • Countershaft end bearings: Retained needle roller bearing
  • Bearing fit on shaft ends: .0005 - .0030 in. loose
  • Bearing fit in case: press fit
    • End play: .004 - .009 in.
  • Second gear
    • On shaft: .001 - .0025 in. loose
  • Low gear
    • On shaft: .0005 - .0016 in. loose
  • Drive gear
    • On shaft: .0005 - .0030 in. loose
  • Clearance between faces
    • Countershaft low an third gear: .028 - .058 in.
    • Countershaft second and third gear: .028 - .058 in.
  • Countershaft end play: .004 - .015 in.
  • Late 1984 - 1985 134)
  • Countershaft end bearings: Retained needle roller bearing
  • Bearing fit on shaft ends: .0005 - .0030 in. loose
  • Bearing fit in case: press fit
  • Second gear
    • On shaft: .001 - .0025 in. loose
  • Low gear
    • On shaft: .0005 - .0016 in. loose
  • Drive gear
    • On shaft: .0005 - .0030 in. loose
  • Clearance between faces
    • Countershaft low an third gear: .028 - .058 in.
    • Countershaft second and third gear: .028 - .058 in.
  • Countershaft end play: .004 - .015 in.

Countershaft and Gears

CountershaftPart No.Notes 135) 136) 137) 138) 139) 140) 141) 142) 143) 144) 145) 146) 147) 148)
1958-E1984
All
35613-58
L1984-1990
All
35613-84
Countershaft Drive GearPart No.Change YearNotes
1958-1985
XL/XLC/XLH/XLCH/XLS
35695-58 (27T)1958
Countershaft 2nd GearPart No.Change YearNotes
1958-1985
XL/XLC/XLH/XLCH/XLS
35750-58 (20T)1958O.D. - 2.448“-2.452” 149)
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. 150)
Countershaft 3rd GearPart No.Change YearNotes
1954-1956 KH
1957-1985 XL/XLC/XLH/XLCH/XLS
(replacement part)
35709-54A (23T) 1957O.D. - 2.648“-2.657” 151)
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. 152)
Countershaft Low GearPart No.Change YearNotes
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)
1973-E1984 XLH/XLCH/XLS/XLX35760-73 (17T)1973
L1984-1985 XLH/XLS/XLX35760-84A (17T)L1984

Countershaft and Oiler Plug

  • There were two different countershafts made for the Sportster 4 speed tranny. In the first picture below, the left one is used on both Ironhead and Evo models from late 1984 until 1990, 153)154) the last year of the 4 speeds.
  • The shaft to the right in the first pic shows an Andrews version of the earlier style ('58-early '84)155) 156) countershaft with the oiler hole in a hollow shaft 157).
  • Dimensions are the same on both style countershafts with exception being the shoulder for first gear which measures 0.0875 in diameter. 158)
  • The oiler plug in the trapdoor catches oil and gravity feeds it through the counter shaft to 1st gear. It will get some amount of splash lube without it, but not as good of a jet of oil as if coming from the plug. 159) The oiler plug sticks outside of the case 7/16“. 160)
  • Before installing the oiler plug, set it off to the side until after you've set / checked your final countershaft endplay. otherwise it'll be in your way. 161)
  • The oiler plug should be a tight interference fit. It should go in and stay in with the engine running and vibrating and carrying on. Upon dis-assembly, many are found to be loose or rather the hole has probably been worn from the aluminum being smashed in and out of a few times without heating the aluminum trapdoor to expand it. This is why you should ALWAYS heat aluminum engine and gearbox casings, wheel hubs etc, with a propane torch before removing or installing bearings. Doing it cold works once, maybe twice, then the hole is worn out. 162)
  • To fix a loose oiler plug, you can take the plug to a machine shop and get them to knurl it. That will increase the diameter by a few thousandths. Then re-install it with Loctite. I would use the red, it is the strongest. But you will then need to use a propane torch to break the Loctite to get it back out. 163)
  • You can also peen the hole to retain the oiler. 164)
  • Late '84 and up trap door does not include a countershaft oiler plug. When installed in this newer trapdoor in older applications, it may easily hit and scrubb the back of the stator due to being too long. It will either need to be machined down for your clearance measurements or the old style trapdoor must be used. 165)
4 Speed Trans Countershaft comparison 166) Early style HD 4 Speed Trans Countershaft 167) Oiler Plug in '77 tranny 168)
Oiler Plug & Countershaft Needle Roller Bearing 169)

Pawl Carriers and Pawl Carrier Support

  • There are 4 different versions of oem 'pawl carriers' and 5 oem versions of the 'pawl carrier support' (shift tower).
  • Here the towers are in order:
1) Used on k models170)#2/#3/#4) next 2 pics. No pic of #3 but the text should suffice.171)
172) #5) changed for clearence of the '77-'90 shifter shaft coming in from the left 173)
Next is the old Trock cast iron tower. By far the best shift fork control
Never breaks, best of both worlds. 174)
Left '72-'76 Shift Tower
(taller shaft than on the right)
Right '77-'90 Shift Tower 175)

Transmission Housing

4 Speed housing inside 1977 XLCH case 176)


1) , 2) , 3) , 4) , 5) , 6)
HD Service Bulletin #M-744 dated April 3, 1979
7) , 14)
HD Service Bulletin #686 dated April 8, 1975
8)
HD Service Bulletin #M-892 dated June 22, 1984
9)
HD Service Bulletin #M-894 dated September 7, 1984
10) , 11)
1979-1985 HD Sportster Parts Catalog pg 35
12)
1952-1959 Spare Parts Catalog for Sportster and K Models pg 11
13)
1954-1976 HD Sporster Parts Catalog pg 13
15)
1977 HD Sportster Parts Catalog Supplement pg 1
16) , 17) , 18)
1979-1985 HD Sportster Parts Catalog pg 15
23) , 24) , 25) , 26) , 32) , 57) , 58) , 59) , 60) , 62) , 72) , 103) , 132)
1970-1978 HD Sportster FSM pg 4-1
27) , 28) , 29) , 30) , 31)
HD Service Bulletin #663 dated May 29, 1974
33) , 34) , 37) , 38) , 39) , 40) , 41) , 42) , 43)
1970-1978 HD Sportster FSM pg 4-6
35) , 61) , 63) , 76) , 77) , 104) , 133)
1979-1985 HD Sportster FSM pg 6-3
36) , 78) , 94) , 95) , 96) , 97) , 98) , 99) , 100) , 101) , 102) , 105) , 134)
1979-1985 HD Sportster FSM pg 6-31
44) , 45) , 46) , 47) , 48)
HD Service Bulletin #541 dated July 15, 1966 pg OC-225
49) , 73) , 74) , 75) , 79) , 81) , 82) , 83) , 84)
1970-1978 HD Sportster FSM pg 1-1
50) , 52)
HD Sportster Parts Catalog 99451-78B pg 71
51) , 53) , 54) , 55)
1979-1985 HD Sportster Parts Catalog pg 55
56)
1979-1985 HD Sportster Parts Catalog pg 57
65) , 66) , 67)
1970-1978 HD Sportster FSM pg 4-2
68)
1970-1978 HD Sportster FSM pg 4-23
69)
HD Sportster Parts Catalog (99451-78B) pg 67
70)
1979-1985 HD Sportster Parts Catalog pg 53
80)
1979-1985 HD Sportster FSM pg 2-1
85) , 86) , 87)
1979-1985 HD Sportster Parts Catalog pg 61
88) , 89) , 90) , 91) , 92) , 93)
1979-1985 HD Sportster FSM pg 6-4
106)
1954-1978 HD Sportster Parts Catalog pg 63, 75
107)
1979-1985 HD Sportster Parts Catalog pg 48
108)
1979 HD Sportster Parts Catalog pg 31
109) , 110) , 111)
1979-1985 HD Sportster Parts Catalog pg 48, 61
112)
HD Service Bulletin #M-858 dated October 7, 1982
113) , 135)
1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25
114) , 137)
1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30
115)
1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 33
116) , 139)
1955-1965 Sportster/KH Model Parts Catalog pg 34
117)
1966 Sportster/KH Model Parts Catalog Supplement
118)
1957-1967 Sportster/KH Model Parts Catalog pg 33
119)
1961-1971 HD Sportster Parts Catalog pg 33,34
120)
1962-1976 HD Sportster Parts Catalog Supplement
121) , 143)
1979 HD Sportster Parts Catalog pg 30,31
122)
1979-1980 HD Sportster Parts Catalog pg 30,31
123)
1979-1981 HD Sportster Parts Catalog pg 39
124)
1979-1981 HD Sportster Parts Catalog pg 39,41
125)
1979-1982 HD Sportster Parts Catalog pg 43
126)
1979-1983 HD Sportster Parts Catalog pg 43,45
127)
1979-1985 HD Sportster Parts Catalog pg 49
128) , 129) , 130) , 131) , 149) , 150) , 151) , 152)
HD Service Bulletin #M906 dated August 19,1985
136)
1958 HD Supplement Spare Parts Catalog for Sportster and K Models pg 25
138)
1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 34
140)
HD Service Bulletin #537 dated March 22, 1866 pg OC-221
141)
1957-1967 HD Sportster/KH Model Parts Catalog pg 34
142)
1961-1971 HD Sportster Parts Catalog pg 34
144)
1979-1980 HD Sportster Parts Catalog pg 31
145)
1979-1981 HD Sportster Parts Catalog pg 41
146)
1979-1982 HD Sportster Parts Catalog pg 44
147)
1979-1983 HD Sportster Parts Catalog pg 45
148) , 153) , 156)
1979-1985 HD Sportster Parts Catalog pg 51
154)
1986-1990 HD Sportster Parts Catalog pg 37
155)
HD Sportster Parts Catalog (99451-78B) pg 63
157)
WI duker
158)
WI_duker of the XLFORUM
160)
IronMick
This website uses cookies for visitor traffic analysis. By using the website, you agree with storing the cookies on your computer.More information