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EVO: Transmission & Final Drive


2004+ 5-Speed Constant Mesh Transmission w/o Trapdoor

  • For 2004, HD redesigned the transmission / engine case to confine the transmission fully within the engine case - the trapdoor was eliminated. In order to service the transmission components, now sealed inside both case halves, the engine cases need to be split.

Clutch

2004 Wet Clutch Information 1)
Clutch plate thicknessFriction plate (fiber)0.0866 in. (± 0.0031 in.) / (2.200 mm ± 0.079 mm)
Steel plate0.0629 in. (± 0.0020 in.) / (1.598 mm ± 0.51 mm)
Maximum allowable warp-age–Friction (fiber) plate 0.0059 in. / (0.150 mm)
–Steel plate 0.0059 in. / (0.150 mm)
Clutch pack service wear limit0.6610 in. min. / (16.787 mm)

Primary Drive (engine to transmission)

YearDomestic Model(s)Engine SprocketClutch SprocketRatio
2004883, 883C2) 34 Teeth57 Teeth1.676:1
1200C, 1200R3)38 Teeth57 Teeth1.500:1
YearHDI, Japan Model(s)Engine SprocketClutch SprocketRatio
2004883, 883C4) 38 Teeth57 Teeth1.500:1
1200C, 1200R5)38 Teeth57 Teeth1.500:1

Transmission

YearOverall Gear Ratios6) Overall Gear Ratios7)
US Models 883 US Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
200410.9447.5245.8344.8064.071 9.4546.5005.0404.1523.517
YearOverall Gear Ratios8) Overall Gear Ratios9)
HDI Models 883 HDI Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
20049.7926.7325.2204.3013.643 9.1396.2834.8724.0143.400
YearOverall Gear Ratios10) Overall Gear Ratios11)
Japan Models 883 Japan Models 1200
1st2nd3rd4th5th 1st2nd3rd4th5th
20049.6476.6335.1434.2483.643 9.0046.1904.8003.9653.400

Final Drive (Trans to Rear Wheel)

YearDomestic Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
2004883/ 883C28 Teeth68 Teeth136 Teeth2.429:1
1200/ 1200R29 Teeth68 Teeth137 Teeth2.345:1
YearHDI / Japan Model(s)Transmission SprocketRear Wheel SprocketSecondary Drive BeltRatio
2004883 / 883C28 Teeth68 Teeth136 Teeth2.429:1
1200 / 1200R30 Teeth68 Teeth137 Teeth2.267:1


1)
2004 HD FSM pg 6-2
2) , 3) , 4) , 5)
2004 HD Sportster FSM pg 6-1
6) , 7) , 8) , 9) , 10) , 11)
Number of engine revolutions to drive rear wheel one revolution.
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