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techtalk:ref:svcproc11 [2023/08/15 02:22] hippysmack [Sub-Documents] |
techtalk:ref:svcproc11 [2024/01/21 06:02] (current) hippysmack |
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| * [[techtalk:ref:svcproc11e|What Causes the 1991-2003 Shift Arm to Scrub the Starter Gear]] | * [[techtalk:ref:svcproc11e|What Causes the 1991-2003 Shift Arm to Scrub the Starter Gear]] | ||
| * [[techtalk:ref:svcproc11i|1991-2003 Shifter Detent Plate Retaining Ring Alternatives]] | * [[techtalk:ref:svcproc11i|1991-2003 Shifter Detent Plate Retaining Ring Alternatives]] | ||
| - | * [[techtalk:ref:svcproc11l|1991-2003 Transmission Gear Inspection and Damage]] | + | * [[techtalk:ref:svcproc11k|Calculating Gear Ratios]] |
| + | * [[techtalk:ref:svcproc11l|Gear Dog Damage: Inspection and Causes]] | ||
| + | * [[techtalk:ref:svcproc11m|Accessing Transmission Gear Damage]] | ||
| ====== Transmission Removal / Installation ====== | ====== Transmission Removal / Installation ====== | ||
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| The detent arm below shows signs on scoring and they are deep across the arm in one place. \\ | The detent arm below shows signs on scoring and they are deep across the arm in one place. \\ | ||
| - | | 1998 1200S Primary ((photo by Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?p=5063081#post5063081)) | | + | | 1998 1200S Primary ((photo by Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/172622-1200s-5-speed-transmission-inspection#post5063081)) | |
| |{{techtalk:ref:svcproc:transmission_inspection_1_by_hippysmack.jpg?direct&500|}}| | |{{techtalk:ref:svcproc:transmission_inspection_1_by_hippysmack.jpg?direct&500|}}| | ||
| ====== Removing the Primary Drive ====== | ====== Removing the Primary Drive ====== | ||
| - | |||
| See also [[techtalk:ref:tools139|Replacing Stator Magnets]] in the tools section of the Sportsterpedia. \\ | See also [[techtalk:ref:tools139|Replacing Stator Magnets]] in the tools section of the Sportsterpedia. \\ | ||
| **Note**: | **Note**: | ||
| Line 85: | Line 86: | ||
| They are less likely to slip and round off the edges of the nuts. Impact-type sockets may be too thick to fit. \\ | They are less likely to slip and round off the edges of the nuts. Impact-type sockets may be too thick to fit. \\ | ||
| - | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) \\ | + | {{:techtalk:ref:tools:engine_sprocket_removal_-_installation_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/169896-2000-883-stator-replacement?t=1823130)) {{:techtalk:ref:tools:clutch_nut_removal_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/169896-2000-883-stator-replacement?t=1823130)) \\ |
| **The engine sprocket and clutch hub should be removed as one unit**. \\ | **The engine sprocket and clutch hub should be removed as one unit**. \\ | ||
| Line 104: | Line 105: | ||
| However they come off is fine as long as they are not dropped. \\ | However they come off is fine as long as they are not dropped. \\ | ||
| - | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | + | {{:techtalk:evo:elec:replacing_the_stator_on_91-03_pic_5_by_tigercreek.jpg?direct&300|}} ((photo by tigercreek of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-electrical/sportster-motorcycle-electrical-and-ignition/169896-2000-883-stator-replacement?t=1823130)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_3_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:priclutch:removing_engine_sprocket_and_clutch_hub_5_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ |
| Make sure you already have a place to put them and a clear walking path before removing them from the engine. \\ | Make sure you already have a place to put them and a clear walking path before removing them from the engine. \\ | ||
| Line 120: | Line 121: | ||
| ====== Disassembly ====== | ====== Disassembly ====== | ||
| - | |||
| You can do this with the tranny laying on a bench but it's easier to prop the shaft ends up so you can lift gears and use both hands on retainers and such. \\ | You can do this with the tranny laying on a bench but it's easier to prop the shaft ends up so you can lift gears and use both hands on retainers and such. \\ | ||
| You can use soft jaws in a bench vise to hold the assembly. \\ | You can use soft jaws in a bench vise to hold the assembly. \\ | ||
| Line 200: | Line 200: | ||
| ===== Trap Door ===== | ===== Trap Door ===== | ||
| - | |||
| Check the trap door with a straightedge to insure there is no warp-age. \\ | Check the trap door with a straightedge to insure there is no warp-age. \\ | ||
| - | |||
| |{{techtalk:ref:svcproc:transmission_inspection_53_by_hippysmack.jpg?direct&400|}}| | |{{techtalk:ref:svcproc:transmission_inspection_53_by_hippysmack.jpg?direct&400|}}| | ||
| - | |||
| ===== Shifter Detent Plate ===== | ===== Shifter Detent Plate ===== | ||
| - | |||
| You may find the shifter detent plate to be leaning at an angle with scoring on the outside face. \\ | You may find the shifter detent plate to be leaning at an angle with scoring on the outside face. \\ | ||
| This is a common condition due to the drum pins walking out of the drum at different times and lengths. \\ | This is a common condition due to the drum pins walking out of the drum at different times and lengths. \\ | ||
| Line 223: | Line 219: | ||
| ===== Shifter Shaft ===== | ===== Shifter Shaft ===== | ||
| - | |||
| The shifter shaft will flop around with the primary cover and that is normal due to the way it is designed. \\ | The shifter shaft will flop around with the primary cover and that is normal due to the way it is designed. \\ | ||
| The primary cover only gives the shaft a place to rest (does not make the shaft rigid during operation). \\ | The primary cover only gives the shaft a place to rest (does not make the shaft rigid during operation). \\ | ||
| Line 256: | Line 251: | ||
| And you may gain several thousandths of meat back with a new spacer. \\ | And you may gain several thousandths of meat back with a new spacer. \\ | ||
| - | | Shift Pawl Bushing ((photo by xLoneRiderx of the XLFORUM http://xlforum.net/forums/showthread.php?t=2078814&highlight=detent&page=18)) | | + | | Shift Pawl Bushing ((photo by xLoneRiderx of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/201713-1250-unhappiness-2020-edition/page18?t=2078814&highlight=detent&page=18)) | |
| |{{:techtalk:ref:svcproc:shift_pawl_spacer_34073-91_by_xloneriderx.jpg?direct&300|}}| | |{{:techtalk:ref:svcproc:shift_pawl_spacer_34073-91_by_xloneriderx.jpg?direct&300|}}| | ||
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| ===== Clutch Basket / Starter Ring Gear ===== | ===== Clutch Basket / Starter Ring Gear ===== | ||
| - | |||
| The back side of the teeth on the starter ring gear may have some wear where they rub against the shifter shaft arm or detent plate. \\ | The back side of the teeth on the starter ring gear may have some wear where they rub against the shifter shaft arm or detent plate. \\ | ||
| This shouldn't hurt the ring gear though. \\ | This shouldn't hurt the ring gear though. \\ | ||
| Line 290: | Line 284: | ||
| This dim is just a dirty one and results will vary. But the point of that measurement is there is that there will be some clearance between the two. \\ | This dim is just a dirty one and results will vary. But the point of that measurement is there is that there will be some clearance between the two. \\ | ||
| If the arm stays against the ring gear when the shaft is lifted, check the starter ring gear for breakage or slippage. \\ | If the arm stays against the ring gear when the shaft is lifted, check the starter ring gear for breakage or slippage. \\ | ||
| - | |||
| | | ||
| {{techtalk:ref:svcproc:transmission_inspection_7_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack)) \\ | {{techtalk:ref:svcproc:transmission_inspection_7_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack)) \\ | ||
| - | {{:techtalk:ref:svcproc:shifter_shaft_to_starter_gear_clearance_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack)) {{:techtalk:ref:svcproc:starter_ring_gear_slippage_by_hippysmack_and_argos587.jpg?direct&400|}} ((combined photos from Hippysmack and argos587 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2079818&page=3)) \\ | + | {{:techtalk:ref:svcproc:shifter_shaft_to_starter_gear_clearance_by_hippysmack.jpg?direct&400|}} ((photo by Hippysmack)) {{:techtalk:ref:svcproc:starter_ring_gear_slippage_by_hippysmack_and_argos587.jpg?direct&400|}} ((combined photos from Hippysmack and argos587 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/202628-1994-transmission-noise-from-shifter/page3?t=2079818&page=3)) \\ |
| - | + | ||
| ===== Transmission Gears ===== | ===== Transmission Gears ===== | ||
| + | Gear Positions. \\ | ||
| + | {{:techtalk:ref:transfinal:1991-2003_sportster_transmission_gears_by_hippysmack.png?direct&600|}} ((drawing by Hippysmack based on illustration from the 1999 Sportster FSM pg 6-26)) | ||
| ==== Countershaft Gear Pics ==== | ==== Countershaft Gear Pics ==== | ||
| - | |||
| | Countershaft 5th - 25 teeth || | | Countershaft 5th - 25 teeth || | ||
| |{{techtalk:ref:svcproc:transmission_inspection_16_c-5-_25t-2_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:svcproc:transmission_inspection_17_c-5-_25t-1_by_hippysmack.jpg?direct&400|}}| | |{{techtalk:ref:svcproc:transmission_inspection_16_c-5-_25t-2_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:svcproc:transmission_inspection_17_c-5-_25t-1_by_hippysmack.jpg?direct&400|}}| | ||
| Line 318: | Line 310: | ||
| ==== Mainshaft Gear Pics ==== | ==== Mainshaft Gear Pics ==== | ||
| - | |||
| | Mainshaft 4th – 32 teeth || | | Mainshaft 4th – 32 teeth || | ||
| |{{techtalk:ref:svcproc:transmission_inspection_26_m-4-_32t-1_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:svcproc:transmission_inspection_27_m-4-_32t-2_by_hippysmack.jpg?direct&400|}}| | |{{techtalk:ref:svcproc:transmission_inspection_26_m-4-_32t-1_by_hippysmack.jpg?direct&400|}}|{{techtalk:ref:svcproc:transmission_inspection_27_m-4-_32t-2_by_hippysmack.jpg?direct&400|}}| | ||
