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* Changes were made in early 1979 production engines to improve the engagement of the clutch teeth between the mainshaft 2nd gear and the clutch gear. 1)
On September 21, 1978 starting with crank case (# 779-26 4- 021), the mainshaft clutch gear thrust washer thickness was decreased .020“ from .232” to .212“ (nominal). The transmission drive sprocket hub width was increased .020” to compensate for the clutch gear change. 2)
This upgrade was recommended as a replacement for earlier transmissions, especially those with severe shifting service where rounding of the gear teeth is likely to occur. 3) A new drive sprocket (35205-79) must be used in conjunction with the new clutch gear, (with the new thinner thrust washer), to retain the proper drive sprocket position. Either install a new washer (35216-79) in the old clutch gear (37448-71) or use a new clutch gear (37448-79) which comes with the new washer already installed. 4)
To convert an old clutch gear to this new one: 5) Remove the thrust washer and needle bearing using a puller, with a 3/4“ collet, pressing out with a rod inserted from the opposite end of gear. If you can't get your hands on the tool, these parts can also be drifted with a hammer and punch, (Caution should be used since this method can damage the bushing). 6) 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.
* . . . 1957-1985 Transmission Trapdoor Pics and Information
Model Years | Part # | Casting# | Retrofit to Years |
1957-1974 | 34844-57 | 34845-54 | - 8) |
1975-1976 | 34844-57A | 34845-54A | 1957-1976 9) 10) |
1977-E1979 | 34844-57B | 34845-54B | - 11) 12) |
L1979-E1984 | 34847-79 | 34846-76F | - 13) |
L1984-1985 | 34847-84 | - 14) |
Click on a pic to enlarge:
1978 4 Speed transmission 18) |
* . . . "The Harton Fix" - Late 84-90 clutch shell magnet fix
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. 33)
Year Model(s) | Engine Sprocket | Clutch Sprocket |
---|---|---|
1971-1978 all models 45) | 34 Teeth | 59 Teeth |
Clutch Sprocket Assembly
1971-1978 XLH 1979 XL 1979-1980 XLS | (37716-71A) 46)47) |
1971-1978 XLCH 1979 XL, XLS | (37717-79) 48)49) |
Early 1979 XLCH | 37701-71A 50) |
1981-Early 1984 XL, XLS, XLX | 37716-81 51) |
Late 1984-1985 all models Clutch Shell & Sprocket w starter gear | 36791-84 52) |
Primary Chain
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. 55)
On the XLH, an electric starter motor and Bendix type drive unit engage the ring gear on the clutch to crank the engine. 61)
1971-1974
1975-1976
1977-1985
1977-1985 shift lever shaft 67) |
1971- 1985 model(s) Overall Gear Ratios | ||||
---|---|---|---|---|
1st | 2nd | 3rd | 4th | |
1970-1971 XLCH69) | 11.74 | 8.50 | 6.43 | 4.66 |
1970-1973 XL, XLH 1972-1973 XLCH70) | 11.16 | 8.08 | 6.11 | 4.42 |
1973-1981 all models71)72) | 10.63 | 7.70 | 5.82 | 4.22 |
1982- Early 1984 all models73) | 10.02 | 7.25 | 5.49 | 3.97 |
Late 1984-1985 all models74) | 10.01 | 7.25 | 5.49 | 3.97 |
Transmission/ Primary Oil Capacity 75) 76): 1.5 pints (24 oz) (710 ml)
Year Model(s) | Transmission Sprocket | Rear Wheel Sprocket |
---|---|---|
1970-1971 XLCH77) | 19 Teeth | 51 Teeth |
1970-1973 XL, XLH78) 1972-1973 XLCH79) | 20 Teeth | 51 Teeth |
1973-1981 all models80) | 21 Teeth | 51 Teeth |
Early 1979 XL, XLCH81) | 19 Teeth 20 Teeth 21 Teeth | 51 Teeth |
Late 1979-1981 XL, XLS, XLX 82) | 21 Teeth | 51 Teeth |
1982-1985 XL, XLS,XLX 83) | 21 Teeth | 48 teeth |
Mainshaft Nut Locking Screw90) | 50 - 60 in. lbs |
Mainshaft Nut91) | 35-65 ft lbs |
Access Cover Screws92) | 13 - 15 ft lbs |
Drain Plug93) | 14-21 ft lbs |
Primary Cover Screws94) | 80 - 110 in. lbs |
Chain Tensioner Stud Nut95) | 8 - 12 ft lbs |
Stator Screws (4 slotted)96) | 20 - 35 in lbs |
Stator Mounting (4 hex socket)97) | 20 - 35 in lbs |
Stator Mounting Torx fasteners98) | 30 - 40 in. lbs |
1971-E1979 XLH/XLCH 103)104) | ||
Clutch Gear 17T | 37448-71 replaced in E1979 by 37448-79 |
|
Clutch Gear Washer (.232“) | 35361-56 replaced in E1979 by 35216-79 (.020" thinner) |
|
Needle Bearings (2) | 35961-52 | |
Clutch Gear Bushing | 37458-52 | |
Drive Sprocket 21T | 35205-52A replaced in E1979 by 35205-79 ( hub width was increased .020”) |
|
Drive Sprocket 20T | 35198-52 | |
Drive Sprocket 19T | 35197-52 | |
L1979 XLCH L1979-E1984 XLH/XLS 105) 106) 1983-1984 XLX 107) |
||
Clutch Gear 17T | 37448-79 | |
Clutch Gear Washer (.212”) | 35216-79 | |
Needle Bearings (2) | 35961-52 | |
Clutch Gear Bushing | 37458-52 | |
Drive Sprocket 21T | 37448-79 | |
Drive Sprocket 20T | 35198-52 | |
Drive Sprocket 19T | 35197-52 | |
L1984-1985 XL/XLS/XLX 108) | ||
Clutch Gear 17T | 37448-84A | |
Clutch Gear Washer (.212“) | 35216-79 | |
Needle Bearings (2) | 35961-52 | |
Clutch Gear Bushing | 37458-52 | |
Drive Sprocket 21T | 35208-84 | |
Drive Sprocket 20T | 35198-52 | |
Drive Sprocket 19T | 35197-52 |
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 109) |
||||
Thrust Washer (Right) | Size | Thrust Washer (Right) | Size | |
35343-73 | .030” | 35352-52 | 0.65“ | |
35344-73 | .040” | 35353-52 | 0.70“ | |
35349-52 | .050” | 35354-52 | 0.75“ | |
35350-52 | .055” | 35326-73 | 0.80“ | |
35351-52 | .060” | 35355-72 | 0.85“ |
Mainshaft | Part # | Change Year | Notes 110) 111) 112) 113) 114) 115) 116) 117) 118) 119) 120) 121) 122) 123) 124) |
---|---|---|---|
1971-1975 XLH/XLCH | 35046-71 | 1971 | |
1971-1983 XLH/XLCH/XLS/XLX | 35046-71A | 1976 | |
L1984-1985 XLH/XLS/XLX | 35036-84A | L1984 | |
Mainshaft Low Gear | Change Year | Notes | |
1956 KH 1957-1985 XL/XLH/XLCH/XLS/XLX | 35277-52A (27T) | 1957 | |
Mainshaft 2nd Gear | Change Year | Notes | |
1956 KH 1957-1985 XL/XLH/XLCH/XLS | 35296-56 (23T) | 1966 | O.D. - 2.648”-2.657“ 125) |
1957-1986 XL/XLH/XLCH/XLS/XLX | 35296-56A (23T) | Early 1986 | O.D. - 2.622”-2.627“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 126) |
Mainshaft 3rd Gear | Change Year | Notes | |
1956 KH 1957-1985 XL/XLH/XLCH/XLS | 35305-56 (20T) | 1957 | O.D. - 2.448”-2.452“. 127) |
1957-1986 XL/XLH/XLCH/XLS/XLX | 35305-56A (20T) | Early 1986 | O.D. - 2.423”-2.428“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 128) |
Countershaft | Part No. | Notes 132) 133) 134) 135) 136) 137) 138) 139) 140) 141) 142) 143) 144) 145) | |
---|---|---|---|
1958-E1984 All | 35613-58 | ||
L1984-1990 All | 35613-84 | ||
Countershaft Drive Gear | Part No. | Change Year | Notes |
1958-1985 XL/XLC/XLH/XLCH/XLS | 35695-58 (27T) | 1958 | |
Countershaft 2nd Gear | Part No. | Change Year | Notes |
1958-1985 XL/XLC/XLH/XLCH/XLS | 35750-58 (20T) | 1958 | O.D. - 2.448”-2.452“ 146) |
1957-1986 XL/XLC/XLH/XLCH/XLS/XLX (replacement part) | 35750-58A (20T) | Early 1986 | O.D. - 2.423”-2.428“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 147) |
Countershaft 3rd Gear | Part No. | Change Year | Notes |
1954-1956 KH 1957-1985 XL/XLC/XLH/XLCH/XLS (replacement part) | 35709-54A (23T) | 1957 | O.D. - 2.648”-2.657“ 148) |
1957-1986 XL/XLC/XLH/XLCH/XLS/XLX (replacement part) | 35709-54B (23T) | Early 1986 | O.D. - 2.622”-2.627“. This was a running change in current 883 transmissions when the early style gear stock was depleted. This new gear can be installed in all Sportsters back to 1957 except 1986 → 1100 transmissions which must use this late style gear. 149) |
Countershaft Low Gear | Part No. | Change Year | Notes |
1957-1971 XL/XLC/XLH/XLCH (replacement part) | 35760-54A (17T) | Late 1966 | Replaced 35760-54 with an added counter-bore on case side to clear the added fillet in the new cases. |
1957-1972 XL/XLH/XLCH (replacement part) | 35760-54B (17T) | 1972 | (with speedometer drive gear) |
1973-E1984 XLH/XLCH/XLS/XLX | 35760-73 (17T) | 1973 | |
L1984-1985 XLH/XLS/XLX | 35760-84A (17T) | L1984 |