Finding a retaining ring / circlip that fits the shaft groove in front of the detent plate is not easy.
Standard retainer rings are usually in mind when grooves and shaft ODs for the groove are machined for retainers.
See also Retaining Ring Sizing Charts in the REF section of the Sportsterpedia.
The OEM shaft groove depth, width and the shaft OD on the end are all made specifically to specs for the flexible retainer clip.
The groove depth is cut significantly deep to match the specs for the flex clip as well as the length of the groove (app .085“).
So a regular circlip to replace the OEM one will require a washer behind it to take up that space between the circlip and the detent plate.
The groove width is cut wide to allow for the clip to shoulder against the detent plate.
The clip will compress and allow the space to be taken up by the plate during a period of side loading then relax to installed width when sideload is off.
The shaft OD is also ground for the specs of the flex ring (app .228”) and poses a problem when trying to use a regular circlip instead of the flex ring.
If you can find a standard circlip that will fit the groove depth, it won't even be as tall as the shaft.
Replacement OEM clips (11019) can be purchased at HD Dealerships or online.
Replacement clips can also be bought from retainer ring manufacturer outlets, as in a Rotorclip part# (EL-31).
The OEM retainer ring is officially called an (External Bowed Locking Ring).
OEM 91-03 detent plate and retainer ring 1) |
There are some considerations when trying to spec an alternate retainer for the detent plate.
Crimped flat washer mod 5) |
Warning: This mod is irreversible. You can not go back to the stock flex clip after performing this mod.
If you change your mind later or the shaft/threads get messed up, you'll need to replace the entire drum.
It is possible to grind the shaft end (where the retainer ring groove is) down to the correct size to cut threads with a die for a nut.
Just keep in mind, this WILL transfer side load onto the shaft itself and in the shear plane of the shaft threads.
The shift shaft itself is hardened but the detent sits on a non-hardened shaft inserted in the end of it.
XLF member MatHormell had his threaded for a nut as shown in the pics below.
The shaft's retainer ring groove is app .228“ (5.8 mm).
And the length from the detent plate (where it should normally and properly sit) to the shaft tip is app .177” (4.5 mm).
That length gives the dimension of the max nut length you can use without altering the nut or using a special nut.
Should you want to use a washer too, just add a shorter nut or cut one down to length.
Nylocks are probably a good idea if you would have the room to help keep the nut from backing off, with Loctite added also.
But Nylocks can not be shortened on the outer side and retain the nylon insert on the end.
Click on any drawing to enlarge.
Below are some patterns for a custom retainer for the detent plate by xLoneRiderx for those with a creative mind and good machinist abilities. 10)
Retainers made from a standard steel washer 6 mm ID, 30 mm OD and 1.5 mm thick.
The retainer is assembled to the detent plate through one or two M3 x 5 mm button head screws (in magenta color) below.
These are made from the same steel washer and with one or two slim cuts that end in a 2 mm drilled hole.
These convert the washer into a solid and elegant “E clip” that will support the drum pins \ detent plate assembly in place.
These cad model solutions may help support the stock pressed pin assembly.