Differences

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--- techtalk:evo:transfinal03 [2022/11/18 18:05]
ixl2relax [The Shifter Shaft Seal]
+++ techtalk:evo:transfinal03 [2023/09/11 13:01]
ixl2relax [Primary Drive (engine to transmission)]
@@ Line 59: / Line 59: @@
 \\
+{{:techtalk:evo:transfinal:1991-2003_sportster_detent_plate_installation_by_hippysmack.png?direct&400|}} ((drawing by Hippysmack)) \\
+\\
   * Another idea to install the detent plate, is to thread the end of the shaft, then use a nut with blue Loctite. ((photos by MatHormell of the XLFORUM http://xlforum.net/forums/showthread.php?t=198227&page=3))
@@ Line 84: / Line 87: @@
 (While this TSB refers to Big Twins with 6-spd transmissions, this shifter shaft seal is used on other models, including the Sportsters.)
-The clearance should be from the deepest edge of the seal cavity in the primary cover. The specific instructions are for the BT models. Therefore, the Sportster models may not be exactly the same details.
+The idea is that if you bottom the seal, the lips around the shaft will be pressed tightly against the primary cover and will not allow the lips to smoothly follow the movement of the shaft. Thus, the tight lips will be thwarting the 'sealing' aspect that the 'garter spring' is designed to enhance.
+The clearance should be from the deepest edge of the seal cavity in the primary cover. The referenced instructions are for the BT models. Therefore, the Sportster models may not be exactly the same.
 BUT, the principle still applies: Insert the seal slightly below that deepest edge of the cavity and don't bottom out the seal. That gives it the best chance to work correctly.
@@ Line 138: / Line 143: @@
 ^Year^883 Model(s)^Transmission Sprocket^Rear Wheel Sprocket^Secondary Drive Belt^Ratio^
-|1991-1992|883 & 883 Hug (chain)((1991 HD Sportster FSM pg 6-1))|21 Teeth|48 Teeth|Chain driven|2.29:1|
+|1991-1992|883 & 883 Hug (chain)((1991 HD Sportster FSM pg 6-1))|21 Teeth Chain Gear|48 Teeth Chain Gear|Chain driven|2.29:1|
 |1991|883 Deluxe((1991 HD Sportster FSM pg 6-1))|27 Teeth|61 Teeth (Belt)|127 Teeth (yellow)|2.26:1|
 |1992|883 Deluxe((1991-1992 HD Sportster FSM pg 6-1))|27 Teeth|61 Teeth (Belt)|128 Teeth (orange)|2.26:1|
@@ Line 156: / Line 161: @@
 ===== Clutch =====
+^  1991-2003 Wet Clutch Information ((1991-1992 HD FSM pg 6-2)) ((1993-1994 HD FSM pg 6-2)) ((1998 HD FSM pg 6-2)) ((2003 HD FSM pg 6-2))  |||
-^  1991-1994, 1998 Wet Clutch Information ((1991-1992 HD FSM pg 6-2)) ((1993-1994 HD FSM pg 6-2)) ((1998 HD FSM pg 6-2))  ^^^
+|Clutch Plate Thickness|Friction Plate (OEM New)|0.0866 in. (± 0.0031 in.) / (2.200 mm ± 0.079 mm)|
-|Clutch plate thickness|Friction plate (fiber)|0.0866 in. (± 0.0031 in.) / (2.200 mm ± 0.079 mm)|
+|:::|Steel Plate|0.0629 in. (± 0.0020 in.) / (1.598 mm ± 0.51 mm)|
-|    |Steel plate|0.0629 in. (± 0.0020 in.) / (1.598 mm ± 0.51 mm)|
+|Max Allowable Warpage|Friction or Steel Plate|0.0059 in. / (0.150 mm)|
-|Maximum allowable warp-age|--Friction (fiber) plate| 0.0059 in. / (0.150 mm)|
+|Service Wear Limit for set of 8 Friction Plates||0.6610 in. min. / (16.787 mm)|
-|    |--Steel plate| 0.0059 in. / (0.150 mm)|
+(For More Clutch Info. see [[techtalk:evo:priclutch01|Clutch Section of Sportsterpedia]])
-|Clutch pack service wear limit|0.6610 in. min. / (16.787 mm)|
@@ Line 177: / Line 174: @@
 |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|
 |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]])
+\\
 ===== Transmission Gearing =====
-  * Internal Gear Ratios are the number of clutch gear revolutions to drive the mainshaft sprocket one revolution.
+  * **Internal Gear Ratios = number of clutch gear revolutions to drive the mainshaft sprocket one revolution.**
-  * Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution.
 ^Year^Internal Gear Ratios^^^^^
@@ Line 189: / Line 187: @@
 |1991-1992 All Models ((1991-1992 HD Sportster FSM pg 6-1))|2.78|2.03|1.49|1.22|1.00|
+  * **Overall Gear Ratios = number of engine revolutions to drive rear wheel one revolution.**
 ^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^^
-^US Models  \\ 883 ((1991-1992 HD Sportster FSM pg 6-1)) ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))  ||||^     ^US Models  \\ 1200 ((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))((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|
 |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 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 \\ 1993-1994 883 (All) ((1993-1994 HD Sportster FSM pg 6-1)) | 10.04|7.32|5.38|4.39|3.61^    |:::|:::|:::|:::|:::|:::|
-|1998 883|9.71|7.12|5.18|4.26|3.61^    |1998 1200|9.04|6.62|4.82|3.97|3.36|
+|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|
+|2003 883((2003 HD Sportster Owner's Manual))|9.717|6.690|5.180|4.267|3.615^    |2003 1200|9.047|6.210((the 2003 Owner's Manual has 6.210 - the FSM has 6.62))|4.823|3.973|3.366|
+| There are some discrepancies between the values in the Owner's Manuals and those in the Factory Service Manual |||||||||||||
 ^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^^
-^HDI Models  \\ 883 ((1993-1994 HD Sportster FSM pg 6-1)) ((1998 Sportster FSM pg 6-1))  |||||^HDI Models  \\ 1200 ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))    |||||||
+^HDI 883 Models ((1993-1994 HD Sportster FSM pg 6-1)) ((1998 Sportster FSM pg 6-1))  |||||^HDI 1200 Models ((1993-1994 HD Sportster FSM pg 6-1))((1998 Sportster FSM pg 6-1))    |||||||
 ^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th|
 |1993-1994 883|9.71|7.12|5.18|4.26|3.61^ |1993-1994|9.04|6.62|4.82|3.97|3.36|
 |1998 883|9.71|7.12|5.18|4.26|3.61^    |1998 1200|9.04|6.62|4.82|3.97|3.36|
 ^Year^Overall Gear Ratios^^^^^^Year^Overall Gear Ratios^^^^^
-^HDI Swiss Models  \\ 883 ((1993-1994 HD Sportster FSM pg 6-1))  |||||^HDI Swiss Models  \\ 1200 ((1993-1994 HD Sportster FSM pg 6-1))   |||||||
+^HDI 883 Swiss Models ((1993-1994 HD Sportster FSM pg 6-1))  |||||^HDI 1200 Swiss Models ((1993-1994 HD Sportster FSM pg 6-1))   |||||||
 ^    |1st|2nd|3rd|4th|5th^     ^    |1st|2nd|3rd|4th|5th|
 |1993-1994|9.05|6.60|4.85|3.96|3.25^   |1993-1994|8.43|6.14|4.51|3.68|3.03|

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