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techtalk:evo:transfinal03 [2023/09/11 13:01]
ixl2relax [Primary Drive (engine to transmission)]
techtalk:evo:transfinal03 [2024/01/09 02:07] (current)
hippysmack
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 Additional References:​\\ Additional References:​\\
-REF section: [[techtalk:​ref:​svcproc11|1998 1200S 5-Speed Transmission Inspection]] from XLForum Thread: ​http://​xlforum.net/​forums/showthread.php?t=1848977+REF section: [[techtalk:​ref:​svcproc11|1998 1200S 5-Speed Transmission Inspection]] from XLForum Thread: ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​172622-1200s-5-speed-transmission-inspection?t=1848977
  
  
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   * The shifter shaft extends out through the primary cover. The foot shift lever is attached onto the shaft splines at the end. The shifter pawl is attached to the shifter assembly allowing the pawl to pull or push the rotating transmission shifter drum into gear as the shifter shaft rotates. In the detailed picture of the pawl, the shifter detent plate has been removed to show the pawl and the end of the shifter drum with it's four protruding pins. That picture shows the shift drum in the neutral position.   * The shifter shaft extends out through the primary cover. The foot shift lever is attached onto the shaft splines at the end. The shifter pawl is attached to the shifter assembly allowing the pawl to pull or push the rotating transmission shifter drum into gear as the shifter shaft rotates. In the detailed picture of the pawl, the shifter detent plate has been removed to show the pawl and the end of the shifter drum with it's four protruding pins. That picture shows the shift drum in the neutral position.
-  * When the primary cover is removed, the shifter assembly has significant motion (wobble) due to being supported at only one end. That end has the shifter bearing which has a relatively loose fit in its case cavity. When the cover is in place, the shifter shaft protrudes thru the cover bushing and stablizes the shifter assembly position. (See the GIF action image in post#1 of this XLForum thread: ​http://​xlforum.net/​forums/showthread.php?​t=2077016) +  * When the primary cover is removed, the shifter assembly has significant motion (wobble) due to being supported at only one end. That end has the shifter bearing which has a relatively loose fit in its case cavity. When the cover is in place, the shifter shaft protrudes thru the cover bushing and stablizes the shifter assembly position. (See the GIF action image in post#1 of this XLForum thread: ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​200057-normal-shifter-shaft-wobble?​t=2077016) 
-  * The shifter drum pins are an issue. Due to the engine heat cycles and the constant push and pull by the shifter pawl, the drum pins tend to come out (somewhat) from their mounting holes, causing the detent plate to skew from perpendicular. This causes stress on the detent plate retaining clip and causes excessive wear on the detent plate due to the skew. Whenever the shifter assembly is accessible, these pins should be homed into the shifter drum with a __minimal__ ​ tap on them with a hammer & punch.((http://​xlforum.net/​forums/showthread.php?​t=1675146)) The pins should have an installed height of (.326" - .334"​). ((HD Tech Tip #47 dated March 1998)) If you find the pin height outside this range, replace the pins or the shift drum as necessary. (Read more here: XLForum Thread, Starting at Post#172 - http://​xlforum.net/​forums/showthread.php?t=2078814&​p=5887502&​postcount=172) +  * The shifter drum pins are an issue. Due to the engine heat cycles and the constant push and pull by the shifter pawl, the drum pins tend to come out (somewhat) from their mounting holes, causing the detent plate to skew from perpendicular. This causes stress on the detent plate retaining clip and causes excessive wear on the detent plate due to the skew. Whenever the shifter assembly is accessible, these pins should be homed into the shifter drum with a __minimal__ ​ tap on them with a hammer & punch.((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​156482-shift-problem-maybe-shift-detent-plate?​t=1675146)) The pins should have an installed height of (.326" - .334"​). ((HD Tech Tip #47 dated March 1998)) If you find the pin height outside this range, replace the pins or the shift drum as necessary. (Read more here: XLForum Thread, Starting at Post#172 - https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-motor-engine/​sportster-motorcycle-motor-top-end/​201713-1250-unhappiness-2020-edition/​page12?​t=2078814&​postcount=172#​post4489773
-  * The factory manual procedure for adjusting the shifter pawl recommends using a #32 drill bit in the alignment hole of the detent plate. Many have had issues when using this procedure, so understand that the goal is to place the shifter pawl such that it is an equal distance from the pins when the shifter drum is in 3rd gear. This can be accomplished with the detent plate removed. Loosen both shifter shaft assembly mounting nuts from their studs. Then rotate the shifter shaft assembly until the pawl is in the right location. Then partially tighten the lower nut, then tighten the upper nut, then finish tightening the lower nut. Make sure the final location is accurately set. This centering is critical to create accurate gear shifts. See these threads for more discussion - http://​xlforum.net/​forums/showthread.php?t=29016 and http://​xlforum.net/​forums/​showthread.php?​t=1556767.+  * The factory manual procedure for adjusting the shifter pawl recommends using a #32 drill bit in the alignment hole of the detent plate. Many have had issues when using this procedure, so understand that the goal is to place the shifter pawl such that it is an equal distance from the pins when the shifter drum is in 3rd gear. This can be accomplished with the detent plate removed. Loosen both shifter shaft assembly mounting nuts from their studs. Then rotate the shifter shaft assembly until the pawl is in the right location. Then partially tighten the lower nut, then tighten the upper nut, then finish tightening the lower nut. Make sure the final location is accurately set. This centering is critical to create accurate gear shifts. See these threads for more discussion - https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​17413-detent-plate?t=29016+and+http://​xlforum.net/​forums/​showthread.php?​t=1556767.
  
 **Shifter Detent Plate, Lever & Spring** **Shifter Detent Plate, Lever & Spring**
   * The detent plate establishes the proper position of the shifter drum to keep the transmission in a particular gear, as well as to define the neutral position. The detent lever (arm) roller lodges between the lobes of the detent plate to resist slipping out of gear or neutral.   * The detent plate establishes the proper position of the shifter drum to keep the transmission in a particular gear, as well as to define the neutral position. The detent lever (arm) roller lodges between the lobes of the detent plate to resist slipping out of gear or neutral.
-  * The original detent plate was upgraded in 1999 (to P/N 33656-90A) to provide a more certain engagement of the gears and to make the neutral location easier to find. It is backward compatible. ((See TT#50 - also Reddtigger'​s comments in this thread - http://​xlforum.net/​forums/showthread.php?​t=222357)) +  * The original detent plate was upgraded in 1999 (to P/N 33656-90A) to provide a more certain engagement of the gears and to make the neutral location easier to find. It is backward compatible. ((See TT#50 - also Reddtigger'​s comments in this thread - https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​51670-has-anyone-replaced-their-sporty-transmission?​t=222357)) 
-  * Due to the above mentioned shifter drum pin issue, the OEM spring clip (P/N 11019) is sometimes replaced with an E-clip and a thin washer in order to help the detent plate keep those pins in place.((http://​xlforum.net/​forums/showthread.php?​t=1675146)) \\ +  * Due to the above mentioned shifter drum pin issue, the OEM spring clip (P/N 11019) is sometimes replaced with an E-clip and a thin washer in order to help the detent plate keep those pins in place.((https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​156482-shift-problem-maybe-shift-detent-plate?​t=1675146)) \\ 
  
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-  * 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))+  * 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 ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​49212-shifter-detent-plate-installation/​page3?​t=198227&​page=3))
  
 {{:​techtalk:​evo:​transfinal:​shifter_detent_plate_fix_1_by_mathormell.jpg?​direct&​400|}} {{:​techtalk:​evo:​transfinal:​shifter_detent_plate_fix_1_by_mathormell.jpg?​direct&​400|}}
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 **See damage from loose Belt Drive Sprocket**\\ **See damage from loose Belt Drive Sprocket**\\
-XLForum Thread: ​http://​xlforum.net/​forums/showthread.php?​t=767676\\ +XLForum Thread: ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-era-specific-and-model-specific/​frame-mount-evo-sportster-talk-1986-2003-models/​93208-bike-crapped-out-may-need-help-from-you-guys?​t=767676\\ 
-XLForum Thread: ​http://​xlforum.net/​forums/showthread.php?t=966388\\+XLForum Thread: ​https://www.xlforum.net/​forum/sportster-motorcycle-forum/​sportster-motorcycle-drivetrain/​sportster-motorcycle-transmission-clutch-primary-secondary-drive/​106994-5th-gear-bearing-walking-out-found-during-belt-replcmnt?t=966388\\
  
  
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 |Service Wear Limit for set of 8 Friction Plates||0.6610 in. min. / (16.787 mm)| |Service Wear Limit for set of 8 Friction Plates||0.6610 in. min. / (16.787 mm)|
 (For More Clutch Info. see [[techtalk:​evo:​priclutch01|Clutch Section of Sportsterpedia]]) (For More Clutch Info. see [[techtalk:​evo:​priclutch01|Clutch Section of Sportsterpedia]])
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 ===== Primary Drive (engine to transmission) ===== ===== Primary Drive (engine to transmission) =====
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 ^    |1st|2nd|3rd|4th|5th^ ​    ​^ ​   |1st|2nd|3rd|4th|5th| ^    |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| |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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 ===== Fastener Torque Specs ===== ===== Fastener Torque Specs =====
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 [[:​techtalk:​menu|{{:​techtalk:​gototechnicalmenu.jpg|}}]] [[:​techtalk:​menu|{{:​techtalk:​gototechnicalmenu.jpg|}}]]
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