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techtalk:evo:transfinal03 [2024/01/09 02:07] – hippysmacktechtalk:evo:transfinal03 [2025/01/20 07:20] (current) – [Primary Drive (engine to transmission)] ixl2relax
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 ===== Mainshaft Fifth Gear ===== ===== Mainshaft Fifth Gear =====
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 **Replacing the Case Bearing for the Mainshaft Fifth Gear** **Replacing the Case Bearing for the Mainshaft Fifth Gear**
  
-See this thread: http://xlforum.net/forums/showthread.php?t=766754+See this thread: http://www.xlforum.net/showthread.php?t=766754
  
  
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 +
  
 ===== Final Drive (Trans to Wheel) ===== ===== Final Drive (Trans to Wheel) =====
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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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 ^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^^ ^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^^
-^US 883 Models ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  ||||^     ^US 1200 Models ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  |||||||+^US 883 Models ((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)) ((1998 Sportster FSM pg 6-1))  ||||^     ^US 1200 Models ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  |||||||
 ^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th| ^    |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, 883 Hug  |10.16|7.41|5.44|4.45|3.66^   |1991-1995|9.35|6.82|5.01|4.09|3.36| 
-|1991-1992 883 Deluxe \\ 1993-1994 883 (All) ((1993-1994 HD Sportster FSM pg 6-1)) | 10.04|7.32|5.38|4.39|3.61^    |:::|:::|:::|:::|:::|:::|+|1991-1992 883 Deluxe \\ 1993-1995 883 (All) ((1993-1994 HD Sportster FSM pg 6-1)) | 10.04|7.32|5.38|4.39|3.61^    |:::|:::|:::|:::|:::|:::|
 |1998-1999 883((1998/99 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| |1998-1999 883((1998/99 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((2000-02 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| |2000-2002 883((2000-02 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|
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 ===== Fastener Torque Specs ===== ===== Fastener Torque Specs =====
  
-==== 1991-1994 Torque Specs ====+==== 1991-1995 Torque Specs ====
  
-|Transmission sprocket nut locking screws((1991-1992 HD Sportster FSM pg 6-2))|| +Footnotes show data sources ((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))((1995 data from the 1995 HD XLH FSM per RandallM of the XLForum.net)) 
-|1991 models (1 screw)((1991-1992 HD Sportster FSM pg 6-2))|50 - 60 in. lbs| +|Transmission sprocket nut locking screws|| 
-|1992 chain drive models (1 screw)((1991-1992 HD Sportster FSM pg 6-2))|50 - 60 in. lbs| +| - 1991 models (1 screw)|50 - 60 in. lbs| 
-|1992 belt drive models (2 screws)((1991-1992 HD Sportster FSM pg 6-2))|7 - 9 ft lbs| +| - 1992 chain drive models (1 screw)|50 - 60 in. lbs| 
-|1993-1994 models ((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)| +| - 1992 belt drive models (2 screws)|7 - 9 ft lbs| 
-|Transmission sprocket nut (**Caution left handed threads**)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|110 - 120 ft lbs (149 - 163 Nm)| +| - 1993-1995 models|90 - 110 in. lbs (10.2 - 12.4 Nm)| 
-|Access door / trapdoor bolts((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|13 - 17 ft lbs (18 - 23 Nm)| +|Transmission sprocket nut (**Caution left handed threads**)|110 - 120 ft lbs (149 - 163 Nm)| 
-|Engine sprocket nut (right hand threads)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|150 - 165 ft lbs (203 - 224 Nm)| +|Access door / trapdoor bolts|13 - 17 ft lbs (18 - 23 Nm)| 
-|Clutch hub nut (**Caution left handed threads**)((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|70 - 80 ft lbs (95 - 108 Nm)|  +|Engine sprocket nut (right hand threads)|150 - 165 ft lbs (203 - 224 Nm)| 
-|Sprocket cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)| +|Clutch hub nut (**Caution left handed threads**)|70 - 80 ft lbs (95 - 108 Nm)|  
-|Drain plug((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|14 - 21 ft lbs (19 - 28 Nm)| +|Sprocket cover screws|90 - 110 in. lbs (10.2 - 12.4 Nm)| 
-|Primary cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|80 - 110 in. lbs (9.0 - 12.4 Nm)| +|Drain plug|14 - 21 ft lbs (19 - 28 Nm)| 
-|Primary/ transmission lubricant level screw((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in. lbs (10.2 - 12.4 Nm)| +|Primary cover screws|80 - 110 in. lbs (9.0 - 12.4 Nm)| 
-|Chain tensioner stud nut((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|20 - 25 ft lbs (27 - 34 Nm)| +|Primary/ transmission lubricant level screw|90 - 110 in. lbs (10.2 - 12.4 Nm)| 
-|Stator Torx fasteners((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|30 - 40 in. lbs (3.4 - 4.5 Nm)| +|Chain tensioner stud nut|20 - 25 ft lbs (27 - 34 Nm)| 
-|Neutral indicator switch (91-92)((1991-1992 HD Sportster FSM pg 6-2))|3 -5 ft lbs| +|Stator Torx fasteners|30 - 40 in. lbs (3.4 - 4.5 Nm)| 
-|Shift lever pinch bolt((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|90 - 110 in lbs (10.2 - 12.4 Nm)| +|Neutral indicator switch (91-92)|3 -5 ft lbs| 
-|Footrest fasteners((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|16 - 28 ft lbs (22 - 38 Nm)| +|Shift lever pinch bolt|90 - 110 in lbs (10.2 - 12.4 Nm)| 
-|Clutch release mechanism screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|22 - 30 in lbs (2.5 - 3.4 Nm)| +|Footrest fasteners|16 - 28 ft lbs (22 - 38 Nm)| 
-|Inspection (Derby) cover screws((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|40 - 60 in lbs (4.5 - 6.8 Nm)| +|Clutch release mechanism screws|22 - 30 in lbs (2.5 - 3.4 Nm)| 
-|Countershaft retaining screw((1991-1992 HD Sportster FSM pg 6-2))((1993-1994 HD Sportster FSM pg 6-2))|13 - 17 in lbs (18 - 23 Nm)|+|Inspection (Derby) cover screws|40 - 60 in lbs (4.5 - 6.8 Nm)| 
 +|Countershaft retaining screw|13 - 17 in lbs (18 - 23 Nm)|
  
-==== 1998 Torque Specs ==== 
  
-|Sprocket nut lock-plate screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs / 10.2-12.4 Nm| +==== 1998 Torque Specs ====
-|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 cover screws((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 Nm)| +
-|Access / trapdoor bolts((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs. (18-23 Nm)| +
-|Engine sprocket nut((1998 HD XLH FSM pg 6-2))|190-210 ft-lbs. (258-285 Nm)| +
-|Clutch hub nut (**caution- left hand threads**)((1998 HD XLH FSM pg 6-2))|70-80 ft-lbs (95-108 Nm)| +
-|Countershaft retaining screw((1998 HD XLH FSM pg 6-2))|13-17 ft-lbs (18-23 Nm)| +
-|Oil Drain plug((1998 HD XLH FSM pg 6-2))|14-21 ft-lbs. (19-28 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)| +
-|Primary chain tensioner stud((1998 HD XLH FSM pg 6-2))|20-25 ft-lbs. (27-34 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)| +
-|Shift lever pinch bolt((1998 HD XLH FSM pg 6-2))|90-110 in-lbs. (10.2-12.4 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)| +
-|Footrest Allen Head bolts (5/16"x18)((1998 HD XLH FSM pg 6-2))|16-28 ft-lbs. (22-38 Nm)|+
  
 +Footnotes show data sources ((1998 HD XLH FSM pg 6-2))
 +|Sprocket nut lock-plate screws|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|| 
 +|Sprocket cover screws|90-110 in-lbs. (10.2-12.4 Nm)|
 +|Access / trapdoor bolts|13-17 ft-lbs. (18-23 Nm)|
 +|Engine sprocket nut|190-210 ft-lbs. (258-285 Nm)|
 +|Clutch hub nut (**caution- left hand threads**)|70-80 ft-lbs (95-108 Nm)|
 +|Countershaft retaining screw|13-17 ft-lbs (18-23 Nm)|
 +|Oil Drain plug|14-21 ft-lbs. (19-28 Nm)| 
 +|Primary cover Allen Head screws (1/4"x 20 threads)|80-110 in-lbs. (9.0-12.4 Nm)|
 +|Primary chain tensioner stud|20-25 ft-lbs. (27-34 Nm)|
 +|Stator Torx Head screws(1/4"x 20 threads)|30-40 in-lbs. (3.4-4.5 Nm)|
 +|Shift lever pinch bolt|90-110 in-lbs. (10.2-12.4 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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