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techtalk:ih:transfinal03 [2023/02/11 03:31]
– [Mainshaft Group] hippysmack |
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techtalk:ih:transfinal03 [2024/01/02 04:01] (current)
– hippysmack |
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| ^[[techtalk:ref:svcproc10#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^ |
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| ====== 1971 - 1985 Sportster Four-Speed Constant Mesh Wet Clutch Transmission & Specifications ====== |
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| * 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. |
| </blockquote> |
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</blockquote> |
| ====== Transmission Access Cover (Trapdoor) ====== |
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| * 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)) |
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| ===== Trapdoor ===== |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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))| |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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)) || |
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| ===== Clutch ===== |
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| * . . . [[techtalk:ref:priclutch01#the_harton_fix_late_84-90_rotor_clutch_shell_magnets|"The Harton Fix" - Late 84-90 clutch shell magnet fix]] |
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| *Type |
| * Wet - Multiple disc |
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| * **1971-1978** ((1970-1978 HD Sportster FSM pg 4-1)) |
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| * Clutch Shell Bearing on clutch gear: .0000 - .0010 in. loose |
| * Clutch Plate max. warp-age: .010 in. |
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| * **Late 1984-1985** ((1979-1985 HD Sportster FSM pg 6-31)) |
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| * Spring Force (dis-engaged):260 lbs. |
| * Clutch Shell Bearing on clutch gear: .0000 in. - .0010 in. loose |
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| ==== 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)) |
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| ==== Shifter Cam Assembly ==== |
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| * 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. |
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| ^Year Model(s)^Engine Sprocket^Clutch Sprocket^ |
| |1971-1978 all models ((1970-1978 HD Sportster FSM pg 1-1)) |34 Teeth|59 Teeth| |
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| **Clutch Sprocket Assembly** |
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| *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)) |
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| ===== 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)) |
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| * 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)) |
* 1979 was the last year you can outfit a Sportster with a kickstarter ((dave76 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/73714-4-speed-info?t=513989)) |
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| ===== Electric Start ===== |
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| |{{:techtalk:ih:transfinal:1977_shifter_shaft_by_nhps.jpg?direct&300|}}| |
| 1977-1985 shift lever shaft ((photo by NHPS of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 ===== |
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| |Late 1984-1985 all models((1979-1985 HD Sportster FSM pg 6-31))|10.01|7.25|5.49|3.97| |
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| **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) ===== |
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| |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| |
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| ===== 1971-1985 Torque Specs ===== |
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| |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| |
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| ==== Late 1984 - 1985 Torque Specs ==== |
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| |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| |
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| ===== Mainshaft Group ===== |
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| * Clutch gear on mainshaft: .001 - .002 in. loose |
| * Mainshaft right side roller bearing: .0006 - .0014 in. loose |
* Mainshaft roller bearings: ((dims provided by Gearhead88 of the XLFORUM httphttps://www.xlforum.net/forumsforum/showthread.php?p=5983327forum-functions/sportsterpedia-com-admin/191119-send-a-note-to-sportsterpedia-admin/page12#post5983327post4620736)) |
| * (9095) Standard = .1562" |
| * (9096) + .0004" = .1566" |
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| * Mainshaft right side roller bearing: .001 - .0034 in. loose |
| * Mainshaft end play: |
| * No axial play (minimum)- .003 in. |
| * With axial play - .020 in. |
| * Clearance between clutch faces: |
| * Mainshaft fourth gear and second gear: .028 - .058 in. |
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| * Mainshaft fourth gear and second gear: .028 - .058 in. |
| * Mainshaft third gear and second gear: .028 - .058 in. |
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| ==== Clutch Gear, Clutch Gear Washer, Needle Bearings & Bushing, Drive Sprocket ==== |
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| |1971-E1979 XLH/XLCH ((1954-1978 HD Sportster Parts Catalog pg 63, 75))((1979-1985 HD Sportster Parts Catalog pg 48))||| |
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| ==== Transmission Mainshaft Shims ==== |
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| |**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))||||| |
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| * Countershaft second and third gear: .028 - .058 in. |
| * Countershaft end play: .004 - .015 in. |
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| ==== Countershaft and Gears ==== |
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| * 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)) |
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* **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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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)) |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-drivetrain/sportster-motorcycle-transmission-clutch-primary-secondary-drive/89263-oiler-plug?t=715410&highlight=oiler+plug)) | |
| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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)) | |
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| ===== Pawl Carriers and Pawl Carrier Support ===== |
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| * 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: |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))| |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/125248-about-the-trans/page3?t=1257259&page=3))| |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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))| |
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| ===== Transmission Housing ===== |
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| |{{: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 httphttps://www.xlforum.net/forumsforum/showthread.phpsportster-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)) || |
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