IH: Transmission & Final Drive

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====== IH: Transmission & Final Drive ======
**Click here for tips on**: 

^[[techtalk:ref:notes303#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^  


====== 1971 - 1985 Sportster Four-Speed Constant Mesh Wet Clutch Transmission & Specifications ======

===== Transmission Changes by Year =====

==== Transmission Changes in 1979 ==== 

<blockquote>  * 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.  ((HD Service Bulletin #M-744 dated April 3, 1979))
    * 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. ((HD Service Bulletin #M-744 dated April 3, 1979))
  
  * 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. ((HD Service Bulletin #M-744 dated April 3, 1979))
    * A new [[techtalk:ih:transfinal03#clutch_gear_clutch_gear_washer_needle_bearings_bushing_drive_sprocket|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. ((HD Service Bulletin #M-744 dated April 3, 1979))
  
  * To convert an old clutch gear to this new one: ((HD Service Bulletin #M-744 dated April 3, 1979))
    * 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). ((HD Service Bulletin #M-744 dated April 3, 1979))
    * 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>
====== Transmission Access Cover (Trapdoor) ======

===== Oil Transfer Hole =====  
 
  * 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))



===== Trapdoor Changes =====


=== L1984 trapdoor (34847-84) ===
Used after July 26, 1984 beginning with crankcase #785 208001, will retrofit to all XL models with an alternator and utilizes two slots for removal. An alignment tool (SNAP-ON 1650) or (MAC LF-12) or equivalent in the shape of a crowbar is recommended by the MoCo to draw the access door from the dowel pins. You can use a propane torch to carefully apply heat to the access door dowel pin area. Do not allow flame to rest on any one area for a prolonged period of time and wipe all the oil from access door prior to heating. Insert the hook end into each slot and gently alternate between the slots to evenly remove the door from the dowel pins. ((HD Service Bulletin #M-892 dated June 22, 1984)) It was sold for parts order as a kit including a retaining ring (11006) for the mainshaft / fourth gear bearing assembly and four T-27 screws (2712). ((HD Service Bulletin #M-894 dated September 7, 1984)) The torx screws contained a thread locker in pellet form on the threads which, when the screw is started in the hole, breaks and releases the compound. As a result, the old screws could not be used. The stator is directly bolted to the door by the four torx locking screws at 30-40 in-lbs. The L84-85 stator (29966-84) ((1979-1985 HD Sportster Parts Catalog pg 35)) has 8 mounting holes with only four being used. To prevent possible chafing of the stator wire, you must use the proper holes when mounting the stator. Starting with the upper right set of holes (1-2)  and numbering clockwise from 1-8, you must use holes number 1, 3, 6 & 7. The 85 stator (29967-84) ((1979-1985 HD Sportster Parts Catalog pg 35)) only has 4 holes. The mainshaft fourth gear bearing rests against a shelf in the trapdoor bore while the retaining ring sits in a groove in the door behind the bearing locking it in place. This beveled retaining ring is installed with the bevel side facing the transmission and the flat side facing the bearing.



|Model Years|Part #|Retrofit to Years|
|1957-1974|34844-57| - ((1952-1959 Spare Parts Catalog for Sportster and K Models pg 11)) |
|1975-1976|34844-57A|1957-1976 ((1954-1976 HD Sporster Parts Catalog pg 13)) ((HD Service Bulletin #686 dated April 8, 1975))|
|1977-E1979|34844-57B| - ((1977 HD Sportster Parts Catalog Supplement pg 1)) ((1979-1985 HD Sportster Parts Catalog pg 15))|
|L1979-E1984|34847-79| - ((1979-1985 HD Sportster Parts Catalog pg 15))|
|L1984-1985|34847-84| - ((1979-1985 HD Sportster Parts Catalog pg 15))|





Click on a pic to enlarge:

|{{: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 http://xlforum.net/forums/showthread.php?t=1920201&highlight=speed+transmission&page=10))  |  1977 4 Speed Trap Door ((photo by Freewheeler of the XLFORUM http://xlforum.net/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8))  |1983 4 Speed ((photo by sc72 http://xlforum.net/forums/showthread.php?t=1717592&highlight=engine+sprocket&page=10))|

|{{: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 http://xlforum.net/forums/showthread.php?t=1981137&page=10))  ||


===== Clutch =====
===== Sub-Documents =====

* . . . [[techtalk:ref:priclutch01#the_harton_fix_late_84-90_rotor_clutch_shell_magnets|"The Harton Fix" - Late 84-90 clutch shell magnet fix]]


\\


----


  *Type
    * Wet - Multiple disc


    * **1971-1978** ((1970-1978 HD Sportster FSM pg 4-1))
    * 8 Drive plates (37985-71), 8 Driven Plates (37992-71A), with an outer drive plate (37987-71) and retaining ring (11053).
    * Back to Front : Backing Plate-F-S-F-S-F-S-F-S-F-S-F-S-F-S-F-S-Outer Drive Plate with retaining ring. 
  * Capacity: 1900 in-lbs (158.33 ft lbs.)    
  * Set up Spring Pressure
      * __1971__: 234 lbs. ((1970-1978 HD Sportster FSM pg 4-1))
      * __1972__: 257 lbs. ((1970-1978 HD Sportster FSM pg 4-1))
    * Spring adjustment
      * __1971 - 1973__: 11/32 in. from outer surface of outer drive plate to outer surface of releasing disc ((1970-1978 HD Sportster FSM pg 4-1))
      * __Late 1974 & later__: 
      * Clutch changes include a new pressure plate (38005-71B) and six spacers (5995) over the studs between the pressure plate and the releasing disc allowing the spring set-up pressure to be set at a controlled amount. A conversion kit (38005-71B), which contained the new pressure plate and spacers, was available to convert 71-E73 models to the new 74 style set-up. The stud holes in the clutch unlined plates (37992-71) were modified to fit loosely over six spacers. New plates have larger oblong holes and round stud holes. ((HD Service Bulletin #663 dated May 29, 1974))
      * Standard Spacers: (5995) - 1.530" long. ((HD Service Bulletin #663 dated May 29, 1974))
        * Shorter spacers to increase the spring tension due to disc lining wear:
          * (5996) - 1.490" long. ((HD Service Bulletin #663 dated May 29, 1974))
          * (5997) - 1.450" long. ((HD Service Bulletin #663 dated May 29, 1974)) \\ Note: The six spring tension nut adjusters (7686) and retainers (37499-71) are no longer used since the clutch spring set-up pressure is adjusted differently with this change. ((HD Service Bulletin #663 dated May 29, 1974)) 
    
    * Clutch bearing: .0005 - .002 in. loose ((1970-1978 HD Sportster FSM pg 4-1)) 
  
  
  *Periodic adjustment of the clutch is required every 2,000 miles to compensate for lining wear. ((1970-1978 HD Sportster FSM pg 4-6))
  *Adjustment may also be necessary with the clutch slipping under load or dragging in the released position. ((1970-1978 HD Sportster FSM pg 4-6)) 

  * **1979- Early 1984** ((1979-1985 HD Sportster FSM pg 6-3))
  * Capacity: 174 ft lbs.
  * Spring Adjustment- Fixed spacers standard length 1.530 in. 
    * Free Length- inner- 2-25/64 in.
      * Wear limit: 2 - 11/32 in.
    * Free Length- outer- 2-25/64 in.
      * Wear limit: 2 - 11/32 in.
  * Clutch Shell Bearing on clutch gear: .0000 - .0010 in. loose
  * Clutch Plate max. warp-age: .010 in.
  
  
  * **Late 1984-1985** ((1979-1985 HD Sportster FSM pg 6-31))  
  * Capacity:174 ft lbs.
  * Spring Force (engaged): 304 lbs.
  * Spring Force (dis-engaged):260 lbs.
  * Clutch Shell Bearing on clutch gear: .0000 in. - .0010 in. loose   
==== 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))

  * Loosen adjuster locknut at primary case and turn adjuster inward until there is a large amount of free play at hand lever. ((1970-1978 HD Sportster FSM pg 4-6))
  * Remove access plug from primary cover to view adjusting screw. ((1970-1978 HD Sportster FSM pg 4-6))
  * Loosen adjusting screw lock nut and turn adjusting screw inward until it becomes harder to turn (starts to release the clutch) and continue turning (app 2 more turns) to be sure clutch is dis-engaged. ((1970-1978 HD Sportster FSM pg 4-6))
  * Adjust all free play out of control cable by turning adjuster outward. Do not put any tension on cable. With all slack in cable taken out (no play at hand lever) tighten the adjuster locknut. ((1970-1978 HD Sportster FSM pg 4-6))
  * Ready for final clutch release adjustment: Loosen the locknut and back off the adjusting screw until the clutch is engaged (pressure is off the screw) then turn screw inward until the point of no free play. Then turn the adjusting screw outward 1/4 - 1/2 turn to establish the correct amount of free play and tighten the lock nut. Check free play at hand lever. you should have 1/8 in. free play. If not, adjust sleeve and tighten lock nut. ((1970-1978 HD Sportster FSM pg 4-6))
  * If clutch slips or drags after these adjustments, it may be necessary to inspect / adjust the clutch springs and / or clutch release mechanism for defects. ((1970-1978 HD Sportster FSM pg 4-6))

==== Shifter Cam Assembly ====


  * 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.
  * The shifter cam assembly is secured to the access cover with a bolt, a lockwasher and 2 dowel pins registering in the access cover.  If the assembly becomes loose, the (press fitted) dowel pins can work loose from the assembly and into the access cover holes. When the dowel pins have successfully worked their way out of the assembly support, the shifter cam will tip causing a bind in the mechanism.  ((HD Service Bulletin #541 dated July 15, 1966 pg OC-225)) 
  
  * If you’re having shifting problems and you’re sure it’s not because of a dragging clutch (before doing exploratory surgery on the internal tranny parts), try removing the chain cover and check for a loose shift assembly bolt. The bolt may appear tight, but it has been known to bottom out in the hole from being slightly too long which allows it to get tight before full clamping force on the assembly. ((HD Service Bulletin #541 dated July 15, 1966 pg OC-225))
  * To properly tighten up the assembly, you can remove the clutch and access cover to check and make sure the dowel pins are properly press fit into the support holes and are a snug fit into the access cover. If the dowels are loose in the cover holes (slight wear), try replacing the standard dowel pins with an oversized pair (+0.001), (+0.002) or (+0.003). ((HD Service Bulletin #541 dated July 15, 1966 pg OC-225)) If the holes are out of round in the access door, the door may have to be replaced. A good machinist could probably re-drill the holes straight to accept bigger pins also. ((HD Service Bulletin #541 dated July 15, 1966 pg OC-225))
  * When re-assembling the shifter assembly to the access cover, be sure the bolt and lockwasher secure it tight to the door. If necessary, you can shorten the bolt by 1/16” (or one thread) with a Dremil tool with a metal cutting blade or a hacksaw. If the bolt still bottoms out, the threaded hole is too shallow and the pawl carrier support may have to be replaced. ((HD Service Bulletin #541 dated July 15, 1966 pg OC-225))
  * Click here for pics and identification of shifter assemblies: [[techtalk:ih:transfinal03#pawl_carriers_and_pawl_carrier_support|Pics of Pawl Carriers and Pawl Carrier Supports]]

===== Primary Drive (engine to transmission) =====
 
^Year Model(s)^Engine Sprocket^Clutch Sprocket^
|1971-1978 all models ((1970-1978 HD Sportster FSM pg 1-1)) |34 Teeth|59 Teeth|


**Clutch Sprocket Assembly**
|1971-1978 XLH \\ 1979 XL \\ 1979-1980 XLS|(37716-71A) ((HD Sportster Parts Catalog 99451-78B pg 71))((1979-1985 HD Sportster Parts Catalog pg 55))|
|1971-1978 XLCH \\ 1979 XL, XLS|(37717-79) ((HD Sportster Parts Catalog 99451-78B pg 71))((1979-1985 HD Sportster Parts Catalog pg 55))|
|Early 1979 XLCH|37701-71A ((1979-1985 HD Sportster Parts Catalog pg 55))|
|1981-Early 1984 XL, XLS, XLX|37716-81 ((1979-1985 HD Sportster Parts Catalog pg 55))|  
|Late 1984-1985 all models \\ Clutch Shell & Sprocket \\ w starter gear|36791-84 ((1979-1985 HD Sportster Parts Catalog pg 57))|

**Primary Chain**
  *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))


===== 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))



  * 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 http://xlforum.net/forums/showthread.php?t=513989))

===== Electric Start =====
On the XLH, an electric starter motor and Bendix type drive unit engage the ring gear on the clutch to crank the engine. ((1970-1978 HD Sportster FSM pg 4-2))

===== Gear Shifter =====
**1971-1974**  
  
  * The shifter is located on the right side of the engine and is foot operated transmitting force through the gear shift shaft, actuating pawl carrier, pawls and gear shifter cam. ((1970-1978 HD Sportster FSM pg 4-2))
  * The shifter cam moves shifter forks which slide a series of gear clutches on the mainshaft and countershaft into mesh with the various gears to obtain the desired ratios. ((1970-1978 HD Sportster FSM pg 4-2))

**1975-1976**

  * To convert shifting from right side to left side, the shifter pedal was moved to the left side of the motorcycle and connected through a cross shaft linkage system to the shifter mechanism on the right side. ((1970-1978 HD Sportster FSM pg 4-23))

**1977-1985**
  * The shifter shaft was redesigned again (34628-75) for 1977 and up models but still leaving it on the left side of the bike. ((HD Sportster Parts Catalog (99451-78B) pg 67)) ((1979-1985 HD Sportster Parts Catalog pg 53))

|{{:techtalk:ih:transfinal:1977_shifter_shaft_by_nhps.jpg?direct&300|}}|
|  1977-1985 shift lever shaft  ((photo by NHPS of the XLFORUM http://xlforum.net/forums/showthread.php?t=1981137&highlight=speed+trans&page=3))  |
===== Transmission =====

  * Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution. ((1970-1978 HD Sportster FSM pg 4-1))


^1971- 1985 model(s) Overall Gear Ratios ^^^^^
^    |1st|2nd|3rd|4th|
|1970-1971 XLCH((1970-1978 HD Sportster FSM pg 1-1))|11.74|8.50|6.43|4.66| 
|1970-1973 XL, XLH \\ 1972-1973 XLCH((1970-1978 HD Sportster FSM pg 1-1))|11.16|8.08|6.11|4.42| 
|1973-1981 all models((1970-1978 HD Sportster FSM pg 1-1))((1979-1985 HD Sportster FSM pg 6-3))|10.63|7.70|5.82|4.22|
|1982- Early 1984 all models((1979-1985 HD Sportster FSM pg 6-3))|10.02|7.25|5.49|3.97|
|Late 1984-1985 all models((1979-1985 HD Sportster FSM pg 6-31))|10.01|7.25|5.49|3.97|

**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) =====

^Year Model(s)^Transmission Sprocket^Rear Wheel Sprocket^
|1970-1971 XLCH((1970-1978 HD Sportster FSM pg 1-1))|19 Teeth|51 Teeth|
|1970-1973 XL, XLH((1970-1978 HD Sportster FSM pg 1-1)) \\ 1972-1973 XLCH((1970-1978 HD Sportster FSM pg 1-1))|20 Teeth|51 Teeth|
|1973-1981 all models((1970-1978 HD Sportster FSM pg 1-1))|21 Teeth|51 Teeth|
|Early 1979 XL, XLCH((1979-1985 HD Sportster Parts Catalog pg 61))|19 Teeth \\ 20 Teeth \\ 21 Teeth |51 Teeth|
|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|


===== 1971-1985 Torque Specs =====

==== 1971 - 1978, FSM Lists No Torque Specs Related to the Transmission ====


==== 1979 - Late 1984 Torque Specs ====

|Clutch Hub Nut((1979-1985 HD Sportster FSM pg 6-4))|110 - 150 ft lbs|
|Mainshaft Nut((1979-1985 HD Sportster FSM pg 6-4))|35 - 65 ft lbs|
|Access Cover Screws((1979-1985 HD Sportster FSM pg 6-4))|13 - 15 ft lbs|
|Drain Plug((1979-1985 HD Sportster FSM pg 6-4))|14 - 21 ft lbs|
|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|


==== Late 1984 - 1985 Torque Specs ==== 

|Mainshaft Nut Locking Screw((1979-1985 HD Sportster FSM pg 6-31))|50 - 60 in. lbs|
|Mainshaft Nut((1979-1985 HD Sportster FSM pg 6-31))|35-65 ft lbs|
|Access Cover Screws((1979-1985 HD Sportster FSM pg 6-31))|13 - 15 ft lbs|
|Drain Plug((1979-1985 HD Sportster FSM pg 6-31))|14-21 ft lbs|
|Primary Cover Screws((1979-1985 HD Sportster FSM pg 6-31))|80 - 110 in. lbs|
|Chain Tensioner Stud Nut((1979-1985 HD Sportster FSM pg 6-31))|8 - 12 ft lbs|
|Stator Screws (4 slotted)((1979-1985 HD Sportster FSM pg 6-31))|20 - 35 in lbs|
|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|









===== Mainshaft Group =====

  * **1971 - 1978** ((1970-1978 HD Sportster FSM pg 4-1))
  * Clutch gear ball bearing in case: .0001 - .0012 in loose
  * Ball bearing on clutch gear: .0001 in. loose - .0009 in. tight
  * Clutch gear on mainshaft: .001 - .002 in. loose
  * Mainshaft right side roller bearing: .0006 - .0014 in. loose  
  * Mainshaft end play: .003 - .009 in. with all axial play removed    
  * Third gear
       * On shaft: .002 - .003 in. loose
       * End play: .012 - .030 in. loose
    
  * **1979 - Early 1984** ((1979-1985 HD Sportster FSM pg 6-3))
  * Clutch gear ball bearing in case: .0001 - .0012 in loose
  * Ball bearing on clutch gear: .0009 in. tight
  * Clutch gear on mainshaft: .001 - .002 in. loose       
  * 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.
         * Mainshaft third gear and second gear: .028 - .058 in.
         
  * **Late 1984 - 1985** ((1979-1985 HD Sportster FSM pg 6-31))
  * Clutch gear ball bearing in case: .0001 - .0012 in loose
  * Ball bearing on clutch gear: .0009 in. tight
  * Clutch gear on mainshaft: .001 - .002 in. loose       
  * Mainshaft right side roller bearing: .001 - .0034 in. loose  
  * Mainshaft end play:
         *Minimum - .009 in.
         *Maximum - .015 in.
  * Clearance between clutch faces:
         * Mainshaft fourth gear and second gear: .028 - .058 in.
         * Mainshaft third gear and second gear: .028 - .058 in.



==== Clutch Gear, Clutch Gear Washer, Needle Bearings & Bushing, Drive Sprocket ====


|1971-E1979 XLH/XLCH ((1954-1978 HD Sportster Parts Catalog pg 63, 75))((1979-1985 HD Sportster Parts Catalog pg 48))|||
|:::|Clutch Gear 17T|37448-71 \\ replaced in E1979 by \\ 37448-79|
|:::|Clutch Gear Washer (.232")|35361-56 \\ replaced in E1979 by \\ 35216-79 \\ ([[techtalk:ih:transfinal03#transmission_changes_in_1979|.020" thinner]])|
|:::|Needle Bearings (2)|35961-52|
|:::|Clutch Gear Bushing|37458-52|
|:::|Drive Sprocket 21T|35205-52A \\ replaced in E1979 by \\ 35205-79 \\ ( [[techtalk:ih:transfinal03#transmission_changes_in_1979|hub width was increased .020”]])|
|:::|Drive Sprocket 20T|35198-52|
|:::|Drive Sprocket 19T|35197-52|
|L1979 XLCH \\ L1979-E1984 XLH/XLS ((1979 HD Sportster Parts Catalog pg 31)) ((1979-1985 HD Sportster Parts Catalog pg 48, 61)) \\ 1983-1984 XLX ((1979-1985 HD Sportster Parts Catalog pg 48, 61))|||
|:::|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 ((1979-1985 HD Sportster Parts Catalog pg 48, 61))|||
|:::|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|

==== Transmission Mainshaft Shims ====


|**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))|||||
|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 and Gears ====

^Mainshaft^Part #^Change Year^Notes ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25)) ((1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30)) ((1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 33)) ((1955-1965 Sportster/KH Model Parts Catalog pg 34)) ((1966 Sportster/KH Model Parts Catalog Supplement)) ((1957-1967 Sportster/KH Model Parts Catalog pg 33)) ((1961-1971 HD Sportster Parts Catalog pg 33,34)) ((1962-1976 HD Sportster Parts Catalog Supplement)) ((1979 HD Sportster Parts Catalog pg 30,31)) ((1979-1980 HD Sportster Parts Catalog pg 30,31)) ((1979-1981 HD Sportster Parts Catalog pg 39)) ((1979-1981 HD Sportster Parts Catalog pg 39,41)) ((1979-1982 HD Sportster Parts Catalog pg 43)) ((1979-1983 HD Sportster Parts Catalog pg 43,45)) ((1979-1985 HD Sportster Parts Catalog pg 49))^
|**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" ((HD Service Bulletin #M906 dated August 19,1985))  |
|**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. ((HD Service Bulletin #M906 dated August 19,1985)) |
^Mainshaft 3rd Gear^^Change Year^Notes^
|**1956 KH** \\ **1957-1985** \\ **XL/XLH/XLCH/XLS**|35305-56 (20T)|1957|O.D. - 2.448"-2.452". ((HD Service Bulletin #M906 dated August 19,1985)) |
|**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. ((HD Service Bulletin #M906 dated August 19,1985)) |

===== Countershaft Group =====

  * **1971 - Early 1978** ((1970-1978 HD Sportster FSM pg 4-1))
  * Countershaft end bearings: Retained needle roller bearing
  * Bearing fit on shaft ends: .0005 - .0029 in. loose
  * Bearing fit in case: press fit
      *End play: .004 - .009 in.
  * Second gear
    * On shaft: .001 - .0025 in. loose
  * Low gear
    * On shaft: .0005 - .0016 in. loose
    * End play: .004 - .009 in. (1971-1978)
  * Drive gear
    * On shaft: .0005 - .0030 in. loose    
    * End play: .004 - .009 in. (1971-1978)
  * Clearance between clutch faces
    * Countershaft low an third gear: .038 - .058 in.      
    * Countershaft second and third gear: .038 - .058 in.  
    * Mainshaft clutch gear and second gear: .043 - .083 in. 
    * Mainshaft third gear and second gear: .043 - .083 in.
  * Shifter end play (1971-1976): .010 - .030 in.


  * **1979-Early 1984** ((1979-1985 HD Sportster FSM pg 6-3))
  * Countershaft end bearings: Retained needle roller bearing
  * Bearing fit on shaft ends: .0005 - .0030 in. loose
  * Bearing fit in case: press fit
      *End play: .004 - .009 in.
  * Second gear
    * On shaft: .001 - .0025 in. loose
  * Low gear
    * On shaft: .0005 - .0016 in. loose    
  * Drive gear
    * On shaft: .0005 - .0030 in. loose      
  * Clearance between faces
    * Countershaft low an third gear: .028 - .058 in.      
    * Countershaft second and third gear: .028 - .058 in. 
  * Countershaft end play: .004 - .015 in.

  * **Late 1984 - 1985** ((1979-1985 HD Sportster FSM pg 6-31))
  * Countershaft end bearings: Retained needle roller bearing
  * Bearing fit on shaft ends: .0005 - .0030 in. loose
  * Bearing fit in case: press fit    
  * Second gear
    * On shaft: .001 - .0025 in. loose
  * Low gear
    * On shaft: .0005 - .0016 in. loose    
  * Drive gear
    * On shaft: .0005 - .0030 in. loose      
  * Clearance between faces
    * Countershaft low an third gear: .028 - .058 in.      
    * Countershaft second and third gear: .028 - .058 in. 
  * Countershaft end play: .004 - .015 in.


==== Countershaft and Gears ====
^Countershaft^Part No.^Notes ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25)) ((1958 HD Supplement Spare Parts Catalog for Sportster and K Models pg 25)) ((1952-1959 HD Spare Parts Catalog for Sportster and K Models pg 30)) ((1953-1963 HD Spare Parts Catalog for Sportster and K Models pg 34)) ((1955-1965 Sportster/KH Model Parts Catalog pg 34)) ((HD Service Bulletin #537 dated March 22, 1866 pg OC-221)) ((1957-1967 HD Sportster/KH Model Parts Catalog pg 34)) ((1961-1971 HD Sportster Parts Catalog pg 34)) ((1979 HD Sportster Parts Catalog pg 30,31)) ((1979-1980 HD Sportster Parts Catalog pg 31)) ((1979-1981 HD Sportster Parts Catalog pg 41)) ((1979-1982 HD Sportster Parts Catalog pg 44)) ((1979-1983 HD Sportster Parts Catalog pg 45)) ((1979-1985 HD Sportster Parts Catalog pg 51))^^
|**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" ((HD Service Bulletin #M906 dated August 19,1985))|
|**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. ((HD Service Bulletin #M906 dated August 19,1985))| 
^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" ((HD Service Bulletin #M906 dated August 19,1985))|
|**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. ((HD Service Bulletin #M906 dated August 19,1985)) | 
^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|  |

===== Countershaft and Oiler Plug =====
  * **There were two different countershafts made for the Sportster 4 speed tranny**. In the first picture below, the left one is used on both Ironhead and Evo models from late 1984 until 1990, ((1979-1985 HD Sportster Parts Catalog pg 51))((1986-1990 HD Sportster Parts Catalog pg 37))  the last year of the 4 speeds.
  * The shaft to the right in the first pic shows an Andrews version of the earlier style ('58-early '84)((HD Sportster Parts Catalog (99451-78B) pg 63)) ((1979-1985 HD Sportster Parts Catalog pg 51)) countershaft with the oiler hole in a hollow shaft ((WI duker)). 
  * 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))

  * **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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=475201&highlight=oiler+plug))
  * You can also peen the hole to retain the oiler. ((ryder rick http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1814835&highlight=oiler+plug))



 




|{{: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 http://xlforum.net/forums/showthread.php?t=1959795&highlight=tranny&page=2))| Early style HD 4 Speed Trans Countershaft ((photo by NHPS of the XLFORUM http://xlforum.net/forums/showthread.php?t=1981137&highlight=speed+trans&page=3))|  Oiler Plug in '77 tranny ((photo by billytoppless of the XLFORUM http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1920201&highlight=speed+transmission&page=8))  |


===== Pawl Carriers and Pawl Carrier Support =====

  * 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:
 


|{{: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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1257259&page=3))|

|{{: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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1257259&page=3))|

|{{: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 http://xlforum.net/forums/showthread.php?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 http://xlforum.net/forums/showthread.php?t=1920201&highlight=speed+transmission&page=12))|

===== Transmission Housing =====


|{{: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 http://xlforum.net/forums/showthread.php?t=1981137&highlight=speed+trans&page=3))  ||











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