Differences
This shows you the differences between two versions of the page.
| Both sides previous revision Previous revision Next revision | Previous revision | ||
|
techtalk:ih:transfinal03 [2018/01/16 01:21] hippysmack [Sub-Documents] |
techtalk:ih:transfinal03 [2024/01/02 04:01] (current) hippysmack |
||
|---|---|---|---|
| Line 3: | Line 3: | ||
| **Click here for tips on**: | **Click here for tips on**: | ||
| - | ^[[techtalk:ref:notes05#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^ | + | ^[[techtalk:ref:svcproc10#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^ |
| ====== 1971 - 1985 Sportster Four-Speed Constant Mesh Wet Clutch Transmission & Specifications ====== | ====== 1971 - 1985 Sportster Four-Speed Constant Mesh Wet Clutch Transmission & Specifications ====== | ||
| Line 22: | Line 21: | ||
| * 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). | * 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. | * 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. | ||
| - | |||
| </blockquote> | </blockquote> | ||
| + | |||
| ====== Transmission Access Cover (Trapdoor) ====== | ====== Transmission Access Cover (Trapdoor) ====== | ||
| Line 30: | Line 29: | ||
| * 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. ((HD Service Bulletin #686 dated April 8, 1975)) | * 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. ((HD Service Bulletin #686 dated April 8, 1975)) | ||
| + | ===== Trapdoor ===== | ||
| + | ==== Sub Documents ==== | ||
| + | * . . . [[techtalk:ih:transfinal03f|1957-1985 Transmission Trapdoor Pics and Information]] | ||
| - | ===== Trapdoor Changes ===== | + | |Model Years|Part #|Casting#|Retrofit to Years| |
| - | + | |1957-1974|34844-57|34845-54| - ((1952-1959 Spare Parts Catalog for Sportster and K Models pg 11)) | | |
| - | |Model Years|Part #|Retrofit to Years| | + | |1975-1976|34844-57A|34845-54A|1957-1976 ((1954-1976 HD Sporster Parts Catalog pg 13)) ((HD Service Bulletin #686 dated April 8, 1975))| |
| - | |1957-1974|34844-57| - ((1952-1959 Spare Parts Catalog for Sportster and K Models pg 11)) | | + | |1977-E1979|34844-57B|34845-54B| - ((1977 HD Sportster Parts Catalog Supplement pg 1)) ((1979-1985 HD Sportster Parts Catalog pg 15))| |
| - | |1975-1976|34844-57A|1957-1976 ((1954-1976 HD Sporster Parts Catalog pg 13)) ((HD Service Bulletin #686 dated April 8, 1975))| | + | |L1979-E1984|34847-79|34846-76F| - ((1979-1985 HD Sportster Parts Catalog pg 15))| |
| - | |1977-E1979|34844-57B| - ((1977 HD Sportster Parts Catalog Supplement pg 1)) ((1979-1985 HD Sportster Parts Catalog pg 15))| | + | |L1984-1985|34847-84| | - ((1979-1985 HD Sportster Parts Catalog pg 15))| |
| - | |L1979-E1984|34847-79| - ((1979-1985 HD Sportster Parts Catalog pg 15))| | + | |
| - | |L1984-1985|34847-84| - ((1979-1985 HD Sportster Parts Catalog pg 15))| | + | |
| - | + | ||
| - | + | ||
| - | + | ||
| Click on a pic to enlarge: | Click on a pic to enlarge: | ||
| |{{:techtalk:ih:transfinal:1977_4_speed_tranny_by_freewheeler.jpg?direct&300|}}| {{:techtalk:ih:transfinal:1977_4_speed_trap_door_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ih:transfinal:1983_4_speed_trany_by_sc72.jpg?direct&300|}}| | |{{:techtalk:ih:transfinal:1977_4_speed_tranny_by_freewheeler.jpg?direct&300|}}| {{:techtalk:ih:transfinal:1977_4_speed_trap_door_by_freewheeler.jpg?direct&300|}}|{{:techtalk:ih:transfinal:1983_4_speed_trany_by_sc72.jpg?direct&300|}}| | ||
| - | | 1977 4 Speed Transmission ((photo by Freewheeler of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=10)) | 1977 4 Speed Trap Door ((photo by Freewheeler of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8)) |1983 4 Speed ((photo by sc72 http://xlforum.net/vbportal/forums/showthread.php?t=1717592&highlight=engine+sprocket&page=10))| | + | | 1977 4 Speed Transmission ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page10?t=1920201&highlight=speed+transmission&page=10)) | 1977 4 Speed Trap Door ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page8?t=1920201&highlight=speed+transmission&page=8)) |1983 4 Speed ((photo by sc72 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160106-where-to-go-from-here/page10?t=1717592&highlight=engine+sprocket&page=10))| |
| |{{:techtalk:ih:transfinal:1978_4_speed_transmission_1_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:transfinal:1978_4_speed_transmission_2_by_ironmick.jpg?direct&300|}}| | |{{:techtalk:ih:transfinal:1978_4_speed_transmission_1_by_ironmick.jpg?direct&300|}}|{{:techtalk:ih:transfinal:1978_4_speed_transmission_2_by_ironmick.jpg?direct&300|}}| | ||
| - | | 1978 4 Speed transmission ((photos by IronMick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1981137&page=10)) || | + | | 1978 4 Speed transmission ((photos by IronMick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/184708-first-time-reassembling-transmission/page10?t=1981137&page=10)) || |
| ===== Clutch ===== | ===== Clutch ===== | ||
| ===== Sub-Documents ===== | ===== Sub-Documents ===== | ||
| - | * . . . [[techtalk:ih:transfinal03a|"The Harton Fix" - Late 84-85 clutch shell magnet fix]] | + | * . . . [[techtalk:ref:priclutch01#the_harton_fix_late_84-90_rotor_clutch_shell_magnets|"The Harton Fix" - Late 84-90 clutch shell magnet fix]] |
| \\ | \\ | ||
| - | |||
| ---- | ---- | ||
| - | |||
| *Type | *Type | ||
| * Wet - Multiple disc | * Wet - Multiple disc | ||
| - | |||
| * **1971-1978** ((1970-1978 HD Sportster FSM pg 4-1)) | * **1971-1978** ((1970-1978 HD Sportster FSM pg 4-1)) | ||
| Line 101: | Line 92: | ||
| * Clutch Shell Bearing on clutch gear: .0000 - .0010 in. loose | * Clutch Shell Bearing on clutch gear: .0000 - .0010 in. loose | ||
| * Clutch Plate max. warp-age: .010 in. | * Clutch Plate max. warp-age: .010 in. | ||
| - | | ||
| | | ||
| * **Late 1984-1985** ((1979-1985 HD Sportster FSM pg 6-31)) | * **Late 1984-1985** ((1979-1985 HD Sportster FSM pg 6-31)) | ||
| Line 108: | Line 98: | ||
| * Spring Force (dis-engaged):260 lbs. | * Spring Force (dis-engaged):260 lbs. | ||
| * Clutch Shell Bearing on clutch gear: .0000 in. - .0010 in. loose | * Clutch Shell Bearing on clutch gear: .0000 in. - .0010 in. loose | ||
| + | |||
| ==== Adjusting Clutch Release Mechanism ==== | ==== 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. ((1970-1978 HD Sportster FSM pg 4-6)) | 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. ((1970-1978 HD Sportster FSM pg 4-6)) | ||
| Line 119: | Line 110: | ||
| ==== Shifter Cam Assembly ==== | ==== 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. | * 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 133: | Line 123: | ||
| ^Year Model(s)^Engine Sprocket^Clutch Sprocket^ | ^Year Model(s)^Engine Sprocket^Clutch Sprocket^ | ||
| |1971-1978 all models ((1970-1978 HD Sportster FSM pg 1-1)) |34 Teeth|59 Teeth| | |1971-1978 all models ((1970-1978 HD Sportster FSM pg 1-1)) |34 Teeth|59 Teeth| | ||
| - | |||
| **Clutch Sprocket Assembly** | **Clutch Sprocket Assembly** | ||
| Line 145: | Line 134: | ||
| *Type primary: 3/8 in. pitch triple chain ((1970-1978 HD Sportster FSM pg 4-1)) | *Type primary: 3/8 in. pitch triple chain ((1970-1978 HD Sportster FSM pg 4-1)) | ||
| *Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine) ((1970-1978 HD Sportster FSM pg 4-1)) | *Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine) ((1970-1978 HD Sportster FSM pg 4-1)) | ||
| - | |||
| ===== Kick Starter ===== | ===== 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. ((1970-1978 HD Sportster FSM pg 4-1)) | 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. ((1970-1978 HD Sportster FSM pg 4-1)) | ||
| - | |||
| - | |||
| * Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in. ((1970-1978 HD Sportster FSM pg 4-1))((1979-1985 HD Sportster FSM pg 6-3)) | * Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in. ((1970-1978 HD Sportster FSM pg 4-1))((1979-1985 HD Sportster FSM pg 6-3)) | ||
| * Crankshaft endplay: .001 - .007 in. ((1970-1978 HD Sportster FSM pg 4-1))((1979-1985 HD Sportster FSM pg 6-3)) | * Crankshaft endplay: .001 - .007 in. ((1970-1978 HD Sportster FSM pg 4-1))((1979-1985 HD Sportster FSM pg 6-3)) | ||
| - | * 1979 was the last year you can outfit a Sportster with a kickstarter ((dave76 http://xlforum.net/vbportal/forums/showthread.php?t=513989&highlight=speed)) | + | * 1979 was the last year you can outfit a Sportster with a kickstarter ((dave76 https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/73714-4-speed-info?t=513989)) |
| ===== Electric Start ===== | ===== Electric Start ===== | ||
| Line 173: | Line 159: | ||
| |{{:techtalk:ih:transfinal:1977_shifter_shaft_by_nhps.jpg?direct&300|}}| | |{{:techtalk:ih:transfinal:1977_shifter_shaft_by_nhps.jpg?direct&300|}}| | ||
| - | | 1977-1985 shift lever shaft ((photo by NHPS of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1981137&highlight=speed+trans&page=3)) | | + | | 1977-1985 shift lever shaft ((photo by NHPS of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/184708-first-time-reassembling-transmission/page3?t=1981137&highlight=speed+trans&page=3)) | |
| ===== Transmission ===== | ===== Transmission ===== | ||
| Line 187: | Line 174: | ||
| |Late 1984-1985 all models((1979-1985 HD Sportster FSM pg 6-31))|10.01|7.25|5.49|3.97| | |Late 1984-1985 all models((1979-1985 HD Sportster FSM pg 6-31))|10.01|7.25|5.49|3.97| | ||
| - | **Transmission/ Primary Oil Capacity** ((1970-1978 HD Sportster FSM pg 1-1)) ((1979-1985 HD Sportster FSM pg 2-1)): **1.5 pints (24 oz) (710 ml)** | + | **Transmission/ Primary Oil Capacity** ((1970-1978 HD Sportster FSM pg 1-1)) ((1979-1985 HD Sportster FSM pg 2-1)): **1.5 pints (24 oz) (710 ml)** |
| ===== Final Drive (Trans to Wheel) ===== | ===== Final Drive (Trans to Wheel) ===== | ||
| Line 197: | Line 185: | ||
| |Late 1979-1981 XL, XLS, XLX ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Teeth |51 Teeth| | |Late 1979-1981 XL, XLS, XLX ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Teeth |51 Teeth| | ||
| |1982-1985 XL, XLS,XLX ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Teeth|48 teeth| | |1982-1985 XL, XLS,XLX ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Teeth|48 teeth| | ||
| - | |||
| ===== 1971-1985 Torque Specs ===== | ===== 1971-1985 Torque Specs ===== | ||
| Line 212: | Line 199: | ||
| |Primary Cover Screws((1979-1985 HD Sportster FSM pg 6-4))|80 - 110 in. lbs| | |Primary Cover Screws((1979-1985 HD Sportster FSM pg 6-4))|80 - 110 in. lbs| | ||
| |Chain Tensioner Stud Nut((1979-1985 HD Sportster FSM pg 6-4))|8 - 12 ft lbs| | |Chain Tensioner Stud Nut((1979-1985 HD Sportster FSM pg 6-4))|8 - 12 ft lbs| | ||
| - | |||
| ==== Late 1984 - 1985 Torque Specs ==== | ==== Late 1984 - 1985 Torque Specs ==== | ||
| Line 225: | Line 211: | ||
| |Stator Mounting (4 hex socket)((1979-1985 HD Sportster FSM pg 6-31))|20 - 35 in lbs| | |Stator Mounting (4 hex socket)((1979-1985 HD Sportster FSM pg 6-31))|20 - 35 in lbs| | ||
| |Stator Mounting Torx fasteners((1979-1985 HD Sportster FSM pg 6-31))|30 - 40 in. lbs| | |Stator Mounting Torx fasteners((1979-1985 HD Sportster FSM pg 6-31))|30 - 40 in. lbs| | ||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| ===== Mainshaft Group ===== | ===== Mainshaft Group ===== | ||
| Line 241: | Line 219: | ||
| * Clutch gear on mainshaft: .001 - .002 in. loose | * Clutch gear on mainshaft: .001 - .002 in. loose | ||
| * Mainshaft right side roller bearing: .0006 - .0014 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: .003 - .009 in. with all axial play removed | * Mainshaft end play: .003 - .009 in. with all axial play removed | ||
| * Third gear | * Third gear | ||
| Line 252: | Line 234: | ||
| * Mainshaft right side roller bearing: .001 - .0034 in. loose | * Mainshaft right side roller bearing: .001 - .0034 in. loose | ||
| * Mainshaft end play: | * Mainshaft end play: | ||
| - | *No axial play (minimum)- .003 in. | + | * No axial play (minimum)- .003 in. |
| - | *With axial play - .020 in. | + | * With axial play - .020 in. |
| * Clearance between clutch faces: | * Clearance between clutch faces: | ||
| * Mainshaft fourth gear and second gear: .028 - .058 in. | * Mainshaft fourth gear and second gear: .028 - .058 in. | ||
| Line 269: | Line 251: | ||
| * Mainshaft fourth gear and second gear: .028 - .058 in. | * Mainshaft fourth gear and second gear: .028 - .058 in. | ||
| * Mainshaft third 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 ==== | ==== Clutch Gear, Clutch Gear Washer, Needle Bearings & Bushing, Drive Sprocket ==== | ||
| - | |||
| |1971-E1979 XLH/XLCH ((1954-1978 HD Sportster Parts Catalog pg 63, 75))((1979-1985 HD Sportster Parts Catalog pg 48))||| | |1971-E1979 XLH/XLCH ((1954-1978 HD Sportster Parts Catalog pg 63, 75))((1979-1985 HD Sportster Parts Catalog pg 48))||| | ||
| Line 301: | Line 280: | ||
| ==== Transmission Mainshaft Shims ==== | ==== 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 ((HD Service Bulletin #M-858 dated October 7, 1982))||||| | |**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 ((HD Service Bulletin #M-858 dated October 7, 1982))||||| | ||
| Line 311: | Line 289: | ||
| |35351-52|.060"^ |35355-72|0.85"| | |35351-52|.060"^ |35355-72|0.85"| | ||
| + | ==== Mainshaft and Gears ==== | ||
| + | |||
| + | ^Mainshaft^Part #^Change Year^Notes ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25)) ((1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30)) ((1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 33)) ((1955-1965 Sportster/KH Model Parts Catalog pg 34)) ((1966 Sportster/KH Model Parts Catalog Supplement)) ((1957-1967 Sportster/KH Model Parts Catalog pg 33)) ((1961-1971 HD Sportster Parts Catalog pg 33,34)) ((1962-1976 HD Sportster Parts Catalog Supplement)) ((1979 HD Sportster Parts Catalog pg 30,31)) ((1979-1980 HD Sportster Parts Catalog pg 30,31)) ((1979-1981 HD Sportster Parts Catalog pg 39)) ((1979-1981 HD Sportster Parts Catalog pg 39,41)) ((1979-1982 HD Sportster Parts Catalog pg 43)) ((1979-1983 HD Sportster Parts Catalog pg 43,45)) ((1979-1985 HD Sportster Parts Catalog pg 49))^ | ||
| + | |**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| | | ||
| + | ^Mainshaft 2nd Gear^^Change Year^Notes^ | ||
| + | |**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)) | | ||
| + | |**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** \\ **1957-1985** \\ **XL/XLH/XLCH/XLS**|35305-56 (20T)|1957|O.D. - 2.448"-2.452". ((HD Service Bulletin #M906 dated August 19,1985)) | | ||
| + | |**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)) | | ||
| ===== Countershaft Group ===== | ===== Countershaft Group ===== | ||
| Line 366: | Line 358: | ||
| * Countershaft end play: .004 - .015 in. | * Countershaft end play: .004 - .015 in. | ||
| - | + | ==== Countershaft and Gears ==== | |
| - | ==== Countershaft Low Gear Changes ==== | + | ^Countershaft^Part No.^Notes ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25)) ((1958 HD Supplement Spare Parts Catalog for Sportster and K Models pg 25)) ((1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30)) ((1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 34)) ((1955-1965 Sportster/KH Model Parts Catalog pg 34)) ((HD Service Bulletin #537 dated March 22, 1866 pg OC-221)) ((1957-1967 HD Sportster/KH Model Parts Catalog pg 34)) ((1961-1971 HD Sportster Parts Catalog pg 34)) ((1979 HD Sportster Parts Catalog pg 30,31)) ((1979-1980 HD Sportster Parts Catalog pg 31)) ((1979-1981 HD Sportster Parts Catalog pg 41)) ((1979-1982 HD Sportster Parts Catalog pg 44)) ((1979-1983 HD Sportster Parts Catalog pg 45)) ((1979-1985 HD Sportster Parts Catalog pg 51))^^ |
| - | + | |**1958-E1984** \\ **All**|35613-58|:::|| | |
| - | ^Countershaft Low Gear -17T^Change Year^Model(s)^Notes^ | + | |**L1984-1990** \\ **All**|35613-84|:::|| |
| - | + | ^Countershaft Drive Gear^Part No.^Change Year^Notes^ | |
| - | |35760-54A \\ 1957-1971 (replacement part) ((HD Service Bulletin #537 dated March 22, 1866 pg OC-221)) ((1954-1967 HD Sportster Parts Catalog pg 34)) ((1954-1971 HD Sportster Parts Catalog pg 34))|Late 1966|XLH/XLCH|Replaced 35760-54 with an added counter-bore on case side to clear the added fillet in the new cases.| | + | |**1958-1985** \\ **XL/XLC/XLH/XLCH/XLS**|35695-58 (27T)|1958| |
| - | |35760-54B \\ 1957-1972 (replacement part) ((1954-1971 HD Sportster Parts Catalog pg 34)) ((1954-1976 HD Sportster Parts Catalog pg 45)) ((1954-1978 HD Sportster Parts Catalog pg 51))|1972|(with speedometer drive gear), | + | ^Countershaft 2nd Gear^Part No.^Change Year^Notes^ |
| - | |35760-73 \\ 1973-Early 1984 ((1954-1976 HD Sportster Parts Catalog pg 45)) ((1954-1978 HD Sportster Parts Catalog pg 51)) ((1979-1985 HD Sportster Parts Catalog pg 51))|1973| | + | |**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))| |
| - | |35760-84A \\ Late 1984-1990 ((1979-1985 HD Sportster Parts Catalog pg 51)) ((1986-1990 HD Sportster Parts Catalog pg 37))|Late 1984| | + | |**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** \\ **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)|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^ | ||
| + | |**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| | | ||
| ===== Countershaft and Oiler Plug ===== | ===== Countershaft and Oiler Plug ===== | ||
| Line 381: | Line 381: | ||
| * Dimensions are the same on both style countershafts with exception being the shoulder for first gear which measures 0.0875 in diameter. ((WI_duker of the XLFORUM)) | * Dimensions are the same on both style countershafts with exception being the shoulder for first gear which measures 0.0875 in diameter. ((WI_duker of the XLFORUM)) | ||
| - | * **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. ((doodah man http://xlforum.net/vbportal/forums/showthread.php?t=1959795&highlight=tranny)) The oiler plug sticks outside of the case 7/16". ((IronMick)) | + | * **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. ((doodah man https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/181946-oiler-plug-in-1988-sportster-tranny?t=1959795&highlight=tranny)) The oiler plug sticks outside of the case 7/16". ((IronMick)) |
| - | * **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. ((doodah man of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8)) | + | * **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. ((doodah man of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page8?t=1920201&highlight=speed+transmission&page=8)) |
| - | * **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. ((Hopper of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=475201&highlight=oiler+plug)) | + | * **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. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/70300-countershaft-oiler-plug-loose?t=475201&highlight=oiler+plug)) |
| - | * **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. ((Hopper of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=475201&highlight=oiler+plug)) | + | * **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. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/70300-countershaft-oiler-plug-loose?t=475201&highlight=oiler+plug)) |
| - | * You can also peen the hole to retain the oiler. ((ryder rick http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8)) | + | * You can also peen the hole to retain the oiler. ((ryder rick https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page8?t=1920201&highlight=speed+transmission&page=8)) |
| - | * **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. ((Aticle by lilwillywilly of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1814835&highlight=oiler+plug)) | + | * **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. ((Aticle by lilwillywilly of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/169174-l84-85-countershaft-oiler-plug?t=1814835&highlight=oiler+plug)) |
| - | + | |{{:techtalk:ih:transfinal:four_speed_countershaft_comparison_by_wi_duker.jpg?direct&300|}}|{{:techtalk:ih:transfinal:4_speed_countershaft_pic_by_nhps.jpg?direct&300|}}|{{:techtalk:ih:transfinal:oiler_plug_in_1977_tranny_by_billytoppless.jpg?direct&300|}}| | |
| - | + | | 4 Speed Trans Countershaft comparison ((photo by WI duker of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/181946-oiler-plug-in-1988-sportster-tranny/page2?t=1959795&highlight=tranny&page=2))| Early style HD 4 Speed Trans Countershaft ((photo by NHPS of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/184708-first-time-reassembling-transmission/page3?t=1981137&highlight=speed+trans&page=3))| Oiler Plug in '77 tranny ((photo by billytoppless of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/89263-oiler-plug?t=715410&highlight=oiler+plug)) | | |
| - | + | ||
| - | + | ||
| - | + | ||
| - | + | ||
| - | + | ||
| - | |{{:techtalk:ih:transfinal:four_speed_countershafts_by_wi_duker.jpg?direct&300|}}|{{:techtalk:ih:transfinal:4_speed_countershaft_by_nhps.jpg?direct&300|}}|{{:techtalk:ih:transfinal:oiler_plug_in_1977_tranny_by_billytoppless.jpg?direct&300|}}| | + | |
| - | | 4 Speed Trans Countershaft comparison ((photo by WI duker of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1959795&highlight=tranny&page=2))| Early style HD 4 Speed Trans Countershaft ((photo by NHPS of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1981137&highlight=speed+trans&page=3))| Oiler Plug in '77 tranny ((photo by billytoppless of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=715410&highlight=oiler+plug)) | | + | |
| |{{:techtalk:ih:transfinal:1977_oiler_plug_and_countershaft_needle_roller_by_freewheeler.jpg?direct&300|}}| | |{{:techtalk:ih:transfinal:1977_oiler_plug_and_countershaft_needle_roller_by_freewheeler.jpg?direct&300|}}| | ||
| - | | Oiler Plug & Countershaft Needle Roller Bearing ((photo by Freewheeler of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8)) | | + | | Oiler Plug & Countershaft Needle Roller Bearing ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page8?t=1920201&highlight=speed+transmission&page=8)) | |
| ===== Pawl Carriers and Pawl Carrier Support ===== | ===== Pawl Carriers and Pawl Carrier Support ===== | ||
| Line 405: | Line 397: | ||
| * There are 4 different versions of oem 'pawl carriers' and 5 oem versions of the 'pawl carrier support' (shift tower). | * 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: | * Here the towers are in order: | ||
| - | |||
| - | |||
| |{{:techtalk:ih:transfinal:shift_tower_1_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:transfinal:shift_tower_2_by_dr_dick.jpg?direct&400|}}| | |{{:techtalk:ih:transfinal:shift_tower_1_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:transfinal:shift_tower_2_by_dr_dick.jpg?direct&400|}}| | ||
| - | |1) Used on k models((photo by DR Dick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1257259&page=3))|#2/#3/#4) next 2 pics. No pic of #3 but the text should suffice.((photo by DR Dick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1257259&page=3))| | + | |1) Used on k models((photo by DR Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))|#2/#3/#4) next 2 pics. No pic of #3 but the text should suffice.((photo by DR Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))| |
| |{{:techtalk:ih:transfinal:shift_tower_3_by_dr_dick.jpg?direct&400|}}|{{:techtalk:ih:transfinal:shift_tower_4_by_dr_dick.jpg?direct&400|}}| | |{{:techtalk:ih:transfinal:shift_tower_3_by_dr_dick.jpg?direct&400|}}|{{:techtalk:ih:transfinal:shift_tower_4_by_dr_dick.jpg?direct&400|}}| | ||
| - | | ((photo by DR Dick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1257259&page=3)) |#5) changed for clearence of the '77-'90 shifter shaft coming in from the left ((photo by DR Dick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1257259&page=3))| | + | | ((photo by DR Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3)) |#5) changed for clearence of the '77-'90 shifter shaft coming in from the left ((photo by DR Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))| |
| |{{:techtalk:ih:transfinal:shift_tower_5_by_dr_dick.jpg?direct&400|}}|{{:techtalk:ih:transfinal:76_and_77_shift_towers_by_freewheeler.jpg?direct&400|}}|| | |{{:techtalk:ih:transfinal:shift_tower_5_by_dr_dick.jpg?direct&400|}}|{{:techtalk:ih:transfinal:76_and_77_shift_towers_by_freewheeler.jpg?direct&400|}}|| | ||
| - | |Next is the old Trock cast iron tower. By far the best shift fork control \\ Never breaks, best of both worlds. ((photo by DR Dick of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1257259&page=3))|Left '72-'76 Shift Tower \\ (taller shaft than on the right)|Right '77-'90 Shift Tower ((photo by Freewheeler of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1920201&highlight=speed+transmission&page=12))| | + | |Next is the old Trock cast iron tower. By far the best shift fork control \\ Never breaks, best of both worlds. ((photo by DR Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))|Left '72-'76 Shift Tower \\ (taller shaft than on the right)|Right '77-'90 Shift Tower ((photo by Freewheeler of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/178668-homebrew-ironhead-transmission-teardown-thread/page12?t=1920201&highlight=speed+transmission&page=12))| |
| ===== Transmission Housing ===== | ===== Transmission Housing ===== | ||
| - | |||
| |{{:techtalk:ih:transfinal:77_xlch_trans_housing_1_by_nhps.jpg?direct&300|}}|{{:techtalk:ih:transfinal:77_xlch_trans_housing_2_by_nhps.jpg?direct&300|}}| | |{{:techtalk:ih:transfinal:77_xlch_trans_housing_1_by_nhps.jpg?direct&300|}}|{{:techtalk:ih:transfinal:77_xlch_trans_housing_2_by_nhps.jpg?direct&300|}}| | ||
| - | | 4 Speed housing inside 1977 XLCH case ((photos by NHPS of the XLFORUM http://xlforum.net/vbportal/forums/showthread.php?t=1981137&highlight=speed+trans&page=3)) || | + | | 4 Speed housing inside 1977 XLCH case ((photos by NHPS of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/184708-first-time-reassembling-transmission/page3?t=1981137&highlight=speed+trans&page=3)) || |
| + | \\ | ||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | |||
| - | \\ | ||
| [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] | ||
