Differences

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--- techtalk:evo:transfinal04 [2022/03/20 01:33] – [Shifter Assembly] hippysmack
+++ techtalk:evo:transfinal04 [2025/06/24 09:13] (current) – [Shifter Assembly] ixl2relax
@@ Line 13: / Line 13: @@
 ===== Shifter Assembly =====
-{{:techtalk:evo:transfinal:shifter-assemby-04later.jpg?400|}}((pic from AB,Frank http://xlforum.net/forums/showthread.php?t=1799188)){{:techtalk:evo:transfinal:shiftershaft-oilseal-37107-06-manborn.jpg?400|}}{{:techtalk:evo:transfinal:shiftershaft-bushing-40574-06.jpg?200|}}
+{{:techtalk:evo:transfinal:shifter-assemby-04later.jpg?400|}}((pic from AB,Frank https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/167512-primary-rattle-noises-wtf-now?t=1799188)){{:techtalk:evo:transfinal:shiftershaft-oilseal-37107-06-manborn.jpg?400|}}{{:techtalk:evo:transfinal:shiftershaft-bushing-40574-06.jpg?200|}}
 **2004-2005 vs 2006+ Shifter Assembly**\\
 Note the following part number differences between 04-05 and 06-later. The 06-later shifter shaft is larger than\\
-the previous version and therefore the hole in the primary cover is larger & the bushing & oil seal is different.
+the previous version and therefore the bushing & oil seal is different.((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/205263-2006-shifter-shaft-assembly-on-a-2004))
 ^ Part Description ^ 2004-05 P/N ^ 2006-later P/N |
@@ Line 25: / Line 25: @@
 | Shaft Washer     |  7019        |  2006-2007 ---- 7019\\ 2008-later ---- 7080  |
 ^ ^ 04-05 Primary Covers P/N ^ 06-later Primary Covers P/N |
-| The 04-05 covers\\ are not inter-\\ changeable with\\ the 06+ versions | Polished - 25430-04\\ Chrome - 25460-04\\ Silver - 25471-04\\ Black - 25307-05 ('05) | Polished - 25430-06\\ Chrome - 25460-06\\ Silver - 25471-06\\ Black - 25307-06\\ Grey - 60830-07 ('07+) |
+| All of these may\\ have the same\\ Internal Casting#\\ (34951-04) which\\ can be confusing. | Polished - 25430-04\\ Chrome - 25460-04\\ Silver - 25471-04\\ Black - 25307-05 ('05) | Polished - 25430-06\\ Chrome - 25460-06\\ Silver - 25471-06\\ Black - 25307-06\\ Grey - 60830-07 ('07+) |
-| All of these may have the same Internal Casting # 34951-04 which can be confusing |||
+| From the factory, the primary cover includes the year-specific bushing based on the cover\\ part number. However, the 04-05 covers are interchangeable with the 06+ versions but the\\ bushing/seal/washer must be matched to the shifter shaft for the model year of the engine. |||
-+__06-later - The outer diameter of the seal is larger, the bushing has a shoulder and presses in place from the inside of the cover. ((oo_buck_us in Post#15 - http://xlforum.net/forums/showthread.php?t=1560232))\\
++04-05 brass bushing is flush in cover - 06-later bushing has a shoulder and presses in place from the inside of the cover. ((oo_buck_us in Post#15 - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/143966-04-primary-cover-on-an-07?t=1560232))\\
 ++_latest P/N is 11000101 with 'garter spring' inside (old P/N 37101-84/A/B - no spring). Dims per James Gasket - 13 x 19 x 4\\
 ... Cometic Equiv of 11000101 is C10213\\
-\\
+===== The Shifter Shaft Seal =====
 **Install On all models:**\\
 The oil seal can be removed without removing the primary cover - remove the lever, then use a pick or screwdriver to pry the seal out of the cavity.
@@ Line 38: / Line 38: @@
 On installs, make sure the shaft is free from debris or rust and be sure to put tape over the splines on the shifter shaft before installing the oil seal to prevent the splines from cutting the seal.
-{{:techtalk:evo:transfinal:wire_brush_shifter_shaft_by_cjburr.jpeg?direct&335|}} ((photo by cjburr of the XLFORUM http://xlforum.net/forums/showthread.php?t=49915)) {{:techtalk:evo:transfinal:shiftershaft-tapeoversplines-manborn.jpg?335|}} \\
+{{:techtalk:evo:transfinal:wire_brush_shifter_shaft_by_cjburr.jpeg?direct&335|}} ((photo by cjburr of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/29955-06-clutch-install?t=49915)) {{:techtalk:evo:transfinal:shiftershaft-tapeoversplines-manborn.jpg?335|}} \\
 The Oil Seal is installed first, followed by the washer/spacer (the '04-'05 Parts Manual may show the **WRONG** order).\\
@@ Line 44: / Line 44: @@
 NOTE: There is a [[http://sportsterpedia.com/lib/exe/fetch.php/pdf-bulletin:tsb1350.pdf|TSB (M-1350)]] related to the 'NEW' Shifter Shaft Seal P/N 11000101 being installed with Special Tool HD-51337. The new seal has a 'garter spring' to help seal the shifter shaft from leaks. In this TSB, the following caution is made: If the tool is not used, install seal to a depth of 0.125-0.135 inches. DO NOT bottom the seal in the bore. Bottoming the seal will damage it and prevent it from sealing properly. (While this bulletin refers to Big Twins with 6-spd transmissions, this shifter shaft seal is used on other models, including the Sportsters.)
-NOTE: Some owners have mistakenly gotten 2006-later covers and installed on 2004-05 engines. Neither stock shifter shaft seals would fit correctly, but purchasing an aftermarket seal, 12mm x 22mm x 5mm R23, seems to fit.((See post#15 from 93trident of the XLForum - http://xlforum.net/forums/showthread.php?t=2079676))
+The idea is that if you bottom the seal, the lips around the shaft will be pressed tightly against the primary cover and will not allow the lips to smoothly follow the movement of the shaft. Thus, the tight lips will be thwarting the 'sealing' aspect that the 'garter spring' is designed to enhance.
+The clearance should be from the deepest edge of the seal cavity in the primary cover. The referenced instructions are for the BT models. Therefore, the Sportster models may not be exactly the same.
+BUT, the principle still applies: Insert the seal slightly below that deepest edge of the cavity and don't bottom out the seal. That gives it the best chance to work correctly.
+NOTE: Be sure to match the right bushing & seal to the shifter shaft of the engine year. An aftermarket seal, 12mm x 22mm x 5mm R23, seems to fit in some cases. The R23 version has double lips compared to single lip on the R21 version. ((See post#15 from 93trident of the XLForum - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/202496-what-s-that-about-then?t=2079676))
 Also see the Sportsterpedia Primary Cover info [[techtalk:evo:priclutch02|HERE]].
@@ Line 53: / Line 59: @@
 Some XLForum reference threads:\\
-http://xlforum.net/forums/showthread.php?t=254258\\
+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/53895-06-carb-to-07-fuel-injection-conversion?t=254258\\
-http://xlforum.net/forums/showthread.php?t=79795\\
+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/39317-shifter-shaft-seal?t=79795\\
-http://xlforum.net/forums/showthread.php?t=1560232 (pics of '04 & '06 primary cover)\\
+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/143966-04-primary-cover-on-an-07?t=1560232 (pics of '04 & '06 primary cover)\\
-http://xlforum.net/forums/showthread.php?t=548729\\
+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/76901-primary-cover-differences-05-vs-06?t=548729\\
-http://xlforum.net/forums/showthread.php?t=1218730\\
+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/123027-06-1200c-primary-oil-leak?t=1218730\\
@@ Line 72: / Line 78: @@
 |    |--Steel plate| 0.0059 in. / (0.150 mm)|
 |Clutch pack service wear limit|0.6610 in. min. / (16.787 mm)|
 ===== Primary Drive (engine to transmission) =====
@@ Line 104: / Line 102: @@
 ^    |1st|2nd|3rd|4th|5th^     |1st|2nd|3rd|4th|5th|
 |2004|9.647|6.633|5.143|4.248|3.643^     |9.004|6.190|4.800|3.965|3.400|
 ===== Mainshaft Fifth Gear =====

Trace: • EVO: Engine Mechanicals • IH: Engine Mechanicals - Sub-01C • EVO: Transmission & Final Drive

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