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techtalk:evo:transfinal03 [2025/01/20 06:41] – [1991-1995 Torque Specs] ixl2relaxtechtalk:evo:transfinal03 [2025/01/20 07:20] (current) – [Primary Drive (engine to transmission)] ixl2relax
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-===== Primary Drive (engine to transmission) ===== 
  
-^Year^Domestic Model^Engine Sprocket^Clutch Sprocket^Ratio| +===== Mainshaft Fifth Gear =====
-|1991-1994 (( -1992 HD Sportster FSM pg 6-1))  (( -1994 HD Sportster FSM pg 6-1))  |All Models|35 Teeth|56 Teeth|1.60:1| +
-|1998 (( HD XLH FSM pg 6-1))  |All Models|35 Teeth|56 Teeth|1.60:1|+
  
-===== Transmission Gearing =====+**1991-E1994 Mainshaft 5th Gear, Bearing & Spacer** 
 +  * 35034-89A - Gear Includes Needle Bearings 
 +    * 8996A - Ball Bearing (older P/N 8996 obsoleted) 
 +    * 33344-85 - Drive Sprocket Spacer
  
-  * **Internal Gear Ratios = number of clutch gear revolutions to drive the mainshaft sprocket one revolution.** +**L1994-2005 Mainshaft 5th Gear, Bearing & Spacer** 
-^Year^Internal Gear Ratios^^^^| +  * 35034-94 - Gear Includes Needle Bearings 
-^US Models|1st|2nd|3rd|4th|5th| +    * 8996A - Ball Bearing 
-|1991-1992 All Models (( -1992 HD Sportster FSM pg 6-1))  |2.78|2.03|1.49|1.22|1.00|+    * 33344-94 - Drive Sprocket Spacer
  
-  * **Overall Gear Ratios = number of engine revolutions to drive rear wheel one revolution.** +\\ 
-^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^| +{{:techtalk:evo:transfinal:mainshaft-5thgear-compare-1994-2006.jpg?600|}}
-^US 883 Models (( -1992 HD Sportster FSM pg 6-1))  (( -1994 HD Sportster FSM pg 6-1))  (( Sportster FSM pg 6-1))    ^^^^^   ^US 1200 Models (( -1992 HD Sportster FSM pg 6-1))  (( -1994 HD Sportster FSM pg 6-1))  (( Sportster FSM pg 6-1))    ^^^^^^| +
-^   |1st|2nd|3rd|4th|5th^   ^   |1st|2nd|3rd|4th|5th| +
-|1991-1992 883, 883 Hug  |10.16|7.41|5.44|4.45|3.66^   |1991-1994|9.35|6.82|5.01|4.09|3.36| +
-|1991-1992 883 Deluxe \\ 1993-1994 883 (All) (( -1994 HD Sportster FSM pg 6-1))  |10.04|7.32|5.38|4.39|3.61^   | ::: | ::: | ::: | ::: | ::: | ::: | +
-|1998-1999 883(( /99 HD Sportster Owner's Manual))  |9.717|7.120|5.180|4.267|3.615^   |1998-1999 1200|9.047|6.629|4.823|3.973|3.366| +
-|2000-2002 883(( -02 HD Sportster Owner's Manual))  |9.71|6.69|5.18|4.27|3.62^   |2000-2002 1200|9.05|6.22|4.82|3.97|3.36| +
-|2003 883(( HD Sportster Owner's Manual))  |9.717|6.690|5.180|4.267|3.615^   |2003 1200|9.047|6.210(( the 2003 Owner's Manual has 6.210 - the FSM has 6.62))  |4.823|3.973|3.366| +
-|There are some discrepancies between the values in the Owner's Manuals and those in the Factory Service Manual||||||||||||| +
-^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^| +
-^HDI 883 Models (( -1994 HD Sportster FSM pg 6-1))  (( Sportster FSM pg 6-1))    ^^^^^^HDI 1200 Models (( -1994 HD Sportster FSM pg 6-1))  (( Sportster FSM pg 6-1))    ^^^^^^| +
-^   |1st|2nd|3rd|4th|5th^   ^   |1st|2nd|3rd|4th|5th| +
-|1993-1994 883|9.71|7.12|5.18|4.26|3.61^ |1993-1994|9.04|6.62|4.82|3.97|3.36| +
-|1998 883|9.71|7.12|5.18|4.26|3.61^   |1998 1200|9.04|6.62|4.82|3.97|3.36| +
-^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^| +
-^HDI 883 Swiss Models (( -1994 HD Sportster FSM pg 6-1))    ^^^^^^HDI 1200 Swiss Models (( -1994 HD Sportster FSM pg 6-1))    ^^^^^^| +
-^   |1st|2nd|3rd|4th|5th^   ^   |1st|2nd|3rd|4th|5th| +
-|1993-1994|9.05|6.60|4.85|3.96|3.25^   |1993-1994|8.43|6.14|4.51|3.68|3.03|+
  
-===== Fastener Torque Specs =====+\\
  
-==== 1991-1994 Torque Specs ====+**Replacing the Case Bearing for the Mainshaft Fifth Gear**
  
-|Transmission sprocket nut locking screws(( -1992 HD Sportster FSM pg 6-2))  || +See this thread: http://www.xlforum.net/showthread.php?t=766754
-|1991 models (1 screw)(( -1992 HD Sportster FSM pg 6-2))  |50 - 60 in. lbs| +
-|1992 chain drive models (1 screw)(( -1992 HD Sportster FSM pg 6-2))  |50 - 60 in. lbs| +
-|1992 belt drive models (2 screws)(( -1992 HD Sportster FSM pg 6-2))  |7 - 9 ft lbs| +
-|1993-1994 models (( -1994 HD Sportster FSM pg 6-2))  |90 - 110 in. lbs (10.2 - 12.4 Nm)| +
-|Transmission sprocket nut (**Caution left handed threads**)(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |110 - 120 ft lbs (149 - 163 Nm)| +
-|Access door / trapdoor bolts(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |13 - 17 ft lbs (18 - 23 Nm)| +
-|Engine sprocket nut (right hand threads)(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |150 - 165 ft lbs (203 - 224 Nm)| +
-|Clutch hub nut (**Caution left handed threads**)(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |70 - 80 ft lbs (95 - 108 Nm)| +
-|Sprocket cover screws(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |90 - 110 in. lbs (10.2 - 12.4 Nm)| +
-|Drain plug(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |14 - 21 ft lbs (19 - 28 Nm)| +
-|Primary cover screws(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |80 - 110 in. lbs (9.0 - 12.4 Nm)| +
-|Primary/ transmission lubricant level screw(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |90 - 110 in. lbs (10.2 - 12.4 Nm)| +
-|Chain tensioner stud nut(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |20 - 25 ft lbs (27 - 34 Nm)| +
-|Stator Torx fasteners(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |30 - 40 in. lbs (3.4 - 4.5 Nm)| +
-|Neutral indicator switch (91-92)(( -1992 HD Sportster FSM pg 6-2))  |3 -5 ft lbs| +
-|Shift lever pinch bolt(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |90 - 110 in lbs (10.2 - 12.4 Nm)| +
-|Footrest fasteners(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |16 - 28 ft lbs (22 - 38 Nm)| +
-|Clutch release mechanism screws(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |22 - 30 in lbs (2.5 - 3.4 Nm)| +
-|Inspection (Derby) cover screws(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |40 - 60 in lbs (4.5 - 6.8 Nm)| +
-|Countershaft retaining screw(( -1992 HD Sportster FSM pg 6-2))  (( -1994 HD Sportster FSM pg 6-2))  |13 - 17 in lbs (18 - 23 Nm)|+
  
-==== 1998 Torque Specs ==== 
  
-|Sprocket nut lock-plate screws(( HD XLH FSM pg 6-2))  |90-110 in-lbs / 10.2-12.4 Nm| +\\
-|Sprocket nut (**caution - left handed threads**)(( HD XLH FSM pg 6-2))   \\ 50 ft-lbs. (67.8 Nm) initially \\ Tighten an additional 30-40 degrees \\ Install lock plate over sprocket nut to align to two opposite threaded mounting holes \\ Tighten sprocket nut additionally if holes don't match up but not to exceed 45 degrees total|| +
-|Sprocket cover screws(( HD XLH FSM pg 6-2))  |90-110 in-lbs. (10.2-12.4 Nm)| +
-|Access / trapdoor bolts(( HD XLH FSM pg 6-2))  |13-17 ft-lbs. (18-23 Nm)| +
-|Engine sprocket nut(( HD XLH FSM pg 6-2))  |190-210 ft-lbs. (258-285 Nm)| +
-|Clutch hub nut (**caution- left hand threads**)(( HD XLH FSM pg 6-2))  |70-80 ft-lbs (95-108 Nm)| +
-|Countershaft retaining screw(( HD XLH FSM pg 6-2))  |13-17 ft-lbs (18-23 Nm)| +
-|Oil Drain plug(( HD XLH FSM pg 6-2))  |14-21 ft-lbs. (19-28 Nm)| +
-|Primary cover Allen Head screws (1/4"x 20 threads)(( HD XLH FSM pg 6-2))  |80-110 in-lbs. (9.0-12.4 Nm)| +
-|Primary chain tensioner stud(( HD XLH FSM pg 6-2))  |20-25 ft-lbs. (27-34 Nm)| +
-|Stator Torx Head screws(1/4"x 20 threads)(( HD XLH FSM pg 6-2))  |30-40 in-lbs. (3.4-4.5 Nm)| +
-|Shift lever pinch bolt(( HD XLH FSM pg 6-2))  |90-110 in-lbs. (10.2-12.4 Nm)| +
-|Clutch inspection (Derby)cover T-27 Torx Head screws(( HD XLH FSM pg 6-2))  |40-60 in-lbs. (4.5-6.8 Nm)| +
-|Footrest Allen Head bolts (5/16"x18)(( HD XLH FSM pg 6-2))  |16-28 ft-lbs. (22-38 Nm)| +
- +
-[[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg?nolink&}}]]+
  
  
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 ^Year^Domestic Model^Engine Sprocket^Clutch Sprocket^Ratio^ ^Year^Domestic Model^Engine Sprocket^Clutch Sprocket^Ratio^
-|1991-1994 ((1991-1992 HD Sportster FSM pg 6-1))((1993-1994 HD Sportster FSM pg 6-1))|All Models|35 Teeth|56 Teeth|1.60:1|+|1991-1995 ((1991-1992 HD Sportster FSM pg 6-1))((1993-1994 HD Sportster FSM pg 6-1))((1995 data from 1995 HD XLH FSM per RandallM of the XLForum.net))|All Models|35 Teeth|56 Teeth|1.60:1|
 |1998 ((1998 HD XLH FSM pg 6-1))|All Models|35 Teeth|56 Teeth|1.60:1| |1998 ((1998 HD XLH FSM pg 6-1))|All Models|35 Teeth|56 Teeth|1.60:1|
 (For More Primary Drive Info, see [[techtalk:evo:priclutch02|Primary Section of Sportsterpedia]]) (For More Primary Drive Info, see [[techtalk:evo:priclutch02|Primary Section of Sportsterpedia]])
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 ==== 1998 Torque Specs ==== ==== 1998 Torque Specs ====
  
-|Sprocket nut lock-plate screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs / 10.2-12.4 Nm| +Footnotes show data sources ((1998 HD XLH FSM pg 6-2)) 
-|Sprocket nut (**caution - left handed threads**)((1998 HD XLH FSM pg 6-2)) \\ 50 ft-lbs. (67.8 Nm) initially \\ Tighten an additional 30-40 degrees \\ Install lock plate over sprocket nut to align to two opposite threaded mounting holes \\ Tighten sprocket nut additionally if holes don't match up but not to exceed 45 degrees total||  +|Sprocket nut lock-plate screws|90-110 in-lbs / 10.2-12.4 Nm| 
-|Sprocket cover screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 Nm)| +|Sprocket nut (**caution - left handed threads**) \\ 50 ft-lbs. (67.8 Nm) initially \\ Tighten an additional 30-40 degrees \\ Install lock plate over sprocket nut to align to two opposite threaded mounting holes \\ Tighten sprocket nut additionally if holes don't match up but not to exceed 45 degrees total||  
-|Access / trapdoor bolts((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs. (18-23 Nm)| +|Sprocket cover screws|90-110 in-lbs. (10.2-12.4 Nm)| 
-|Engine sprocket nut((1998 HD XLH FSM pg 6-2))|190-210 ft-lbs. (258-285 Nm)| +|Access / trapdoor bolts|13-17 ft-lbs. (18-23 Nm)| 
-|Clutch hub nut (**caution- left hand threads**)((1998 HD XLH FSM pg 6-2))|70-80 ft-lbs (95-108 Nm)| +|Engine sprocket nut|190-210 ft-lbs. (258-285 Nm)| 
-|Countershaft retaining screw((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs (18-23 Nm)| +|Clutch hub nut (**caution- left hand threads**)|70-80 ft-lbs (95-108 Nm)| 
-|Oil Drain plug((1998 HD XLH FSM pg 6-2))|14-21 ft-lbs. (19-28 Nm)|  +|Countershaft retaining screw|13-17 ft-lbs (18-23 Nm)| 
-|Primary cover Allen Head screws (1/4"x 20 threads)((1998 HD XLH FSM pg 6-2))|80-110 in-lbs. (9.0-12.4 Nm)| +|Oil Drain plug|14-21 ft-lbs. (19-28 Nm)|  
-|Primary chain tensioner stud((1998 HD XLH FSM pg 6-2))|20-25 ft-lbs. (27-34 Nm)| +|Primary cover Allen Head screws (1/4"x 20 threads)|80-110 in-lbs. (9.0-12.4 Nm)| 
-|Stator Torx Head screws(1/4"x 20 threads)((1998 HD XLH FSM pg 6-2))|30-40 in-lbs. (3.4-4.5 Nm)| +|Primary chain tensioner stud|20-25 ft-lbs. (27-34 Nm)| 
-|Shift lever pinch bolt((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 Nm)| +|Stator Torx Head screws(1/4"x 20 threads)|30-40 in-lbs. (3.4-4.5 Nm)| 
-|Clutch inspection (Derby)cover T-27 Torx Head screws((1998 HD XLH FSM pg 6-2))|40-60 in-lbs. (4.5-6.8 Nm)| +|Shift lever pinch bolt|90-110 in-lbs. (10.2-12.4 Nm)| 
-|Footrest Allen Head bolts (5/16"x18)((1998 HD XLH FSM pg 6-2))|16-28 ft-lbs. (22-38 Nm)| +|Clutch inspection (Derby)cover T-27 Torx Head screws|40-60 in-lbs. (4.5-6.8 Nm)| 
 +|Footrest Allen Head bolts (5/16"x18)|16-28 ft-lbs. (22-38 Nm)|
  
  
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