Additional References:
REF section: 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
(Click any picture to see a full-sized version)
1) 2)
Overall Gearing is a ratio of the number of engine revolutions to drive the rear wheel one revolution. See the Gearing Chart in this section.
Primary / Transmission fluid capacity is considered 32 oz. (946 ml) when fully dry3) . However, it is typical to only need 28-30oz
when doing a typical oil change. Be sure to refill the cavity so that the level is just above the bottom of the clutch basket.
Shifter Assembly, Shaft, Pawl & Shifter Drum
Shifter Detent Plate, Lever & Spring
Part Description | 1991-1993 P/N | 1994-2003 P/N |
---|---|---|
Shifter Shaft | 34015-91 | |
Primary Cover | 25430-89A+ | 25430-94A+ |
Shaft Bushing | 40520-63 | |
Shaft Oil Seal | 11000101++ | |
Shaft Washer | 7019 |
+__latest P/N
++_latest P/N is 11000101 with 'garter spring' inside (old P/N 37101-84/A/B - no spring). Dims per James Gasket - 13 x 19 x 4
… Cometic Equiv of 11000101 is C10213
(Click any picture to see a full-sized version)
Install On all models:
The oil seal can be removed without removing the primary cover - remove the lever, then use a pick or screwdriver to pry the seal out of the cavity.
On installs, make sure the shaft is free from debris or rust and be sure to put tape over the splines on the shifter shaft before installing the oil seal to prevent the splines from cutting the seal.
The Oil Seal is installed first, followed by the washer/spacer.
For 1986-2005, the new shifter shaft oil seal is P/N 11000101. It replaces P/N 37101-84B.
NOTE: There is a TSB (M-1350) related to the 'NEW' Shifter Shaft Seal P/N 11000101 being installed with Special Tool HD-51337. The new seal has a 'garter spring' to help seal the shifter shaft from leaks. In this TSB, the following caution is made: If the tool is not used, install seal to a depth of 0.125-0.135 inches. DO NOT bottom the seal in the bore. This allows the spring to keep the lips of the seal against the shaft. Bottoming the seal will damage it and prevent it from sealing properly.
(While this TSB refers to Big Twins with 6-spd transmissions, this shifter shaft seal is used on other models, including the Sportsters.)
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.
To increase the tightness of the oil seal (as often suggested by SportsterPaul), after installing the rubber washer, you might install one or two o-rings to take up the gap between the shift lever and the washer. The o-rings do not seal against leaking oil but, instead, they put additional pressure on the oil seal in the primary cover cavity, which may help if you have a leaking seal. (But be sure you are installing the seal correctly as mentioned above, not bottoming in the bore.)
A couple ways of removing the seal:
10) 11) 12)
1991-E1994 Mainshaft 5th Gear, Bearing & Spacer
L1994-2005 Mainshaft 5th Gear, Bearing & Spacer
Replacing the Case Bearing for the Mainshaft Fifth Gear
See this thread: http://xlforum.net/forums/showthread.php?t=766754
Final Drive Sprocket Torque | |||||
---|---|---|---|---|---|
Nut Description | Nut Size | Tightening Torque | Notes | ||
1991-92 Chain | 1-7/8“ Nut - Left-hand Threads | 110-120 ft-lbs | Max 150ft-lbs | ||
1991-94 Belt | 1-7/8” Nut - Left-hand Threads | 110-120 ft-lbs | Max 150ft-lbs | ||
1995-03 Belt | Tighten to 50ft-lbs, then add 30°-40° more rotation | ||||
(use only 2 or 3 drops of RED threadlocker on this nut) | |||||
Be sure to use a sprocket locking tool when removing or installing the Sprocket Nut |
Year | 883 Model(s) | Transmission Sprocket | Rear Wheel Sprocket | Secondary Drive Belt | Ratio |
---|---|---|---|---|---|
1991-1992 | 883 & 883 Hug (chain)15) | 21 Teeth Chain Gear | 48 Teeth Chain Gear | Chain driven | 2.29:1 |
1991 | 883 Deluxe16) | 27 Teeth | 61 Teeth (Belt) | 127 Teeth (yellow) | 2.26:1 |
1992 | 883 Deluxe17) | 27 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.26:1 |
1993-2003 | 883 all models | 27 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.26:1 |
Year | 1200 Model(s) | Transmission Sprocket | Rear Wheel Sprocket | Secondary Drive Belt | Ratio |
1991-2003 | 1200 all models | 29 Teeth | 61 Teeth (Belt) | 128 Teeth (orange) | 2.10:1 |
See damage from loose Belt Drive Sprocket
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: 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
1991-2003 Wet Clutch Information 18) 19) 20) 21) | ||
---|---|---|
Clutch Plate Thickness | Friction Plate (OEM New) | 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) | |
Max Allowable Warpage | Friction or Steel Plate | 0.0059 in. / (0.150 mm) |
Service Wear Limit for set of 8 Friction Plates | 0.6610 in. min. / (16.787 mm) |
(For More Clutch Info. see Clutch Section of Sportsterpedia)
Year | Domestic Model | Engine Sprocket | Clutch Sprocket | Ratio |
---|---|---|---|---|
1991-1994 22)23) | All Models | 35 Teeth | 56 Teeth | 1.60:1 |
1998 24) | All Models | 35 Teeth | 56 Teeth | 1.60:1 |
(For More Primary Drive Info, see Primary Section of Sportsterpedia)
Year | Internal Gear Ratios | ||||
---|---|---|---|---|---|
US Models | 1st | 2nd | 3rd | 4th | 5th |
1991-1992 All Models 25) | 2.78 | 2.03 | 1.49 | 1.22 | 1.00 |
Year | Overall Gear Ratios | Year | Overall Gear Ratios | |||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
US 883 Models 26) 27)28) | US 1200 Models 29) 30)31) | |||||||||||
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) 32) | 10.04 | 7.32 | 5.38 | 4.39 | 3.61 | |||||||
1998-1999 88333) | 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 88334) | 9.71 | 6.69 | 5.18 | 4.27 | 3.62 | 2000-2002 1200 | 9.05 | 6.22 | 4.82 | 3.97 | 3.36 | |
2003 88335) | 9.717 | 6.690 | 5.180 | 4.267 | 3.615 | 2003 1200 | 9.047 | 6.21036) | 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 883 Models 37) 38) | HDI 1200 Models 39)40) | |||||||||||
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 883 Swiss Models 41) | HDI 1200 Swiss Models 42) | |||||||||||
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 |
Transmission sprocket nut locking screws43) | |
1991 models (1 screw)44) | 50 - 60 in. lbs |
1992 chain drive models (1 screw)45) | 50 - 60 in. lbs |
1992 belt drive models (2 screws)46) | 7 - 9 ft lbs |
1993-1994 models 47) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Transmission sprocket nut (Caution left handed threads)48)49) | 110 - 120 ft lbs (149 - 163 Nm) |
Access door / trapdoor bolts50)51) | 13 - 17 ft lbs (18 - 23 Nm) |
Engine sprocket nut (right hand threads)52)53) | 150 - 165 ft lbs (203 - 224 Nm) |
Clutch hub nut (Caution left handed threads)54)55) | 70 - 80 ft lbs (95 - 108 Nm) |
Sprocket cover screws56)57) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Drain plug58)59) | 14 - 21 ft lbs (19 - 28 Nm) |
Primary cover screws60)61) | 80 - 110 in. lbs (9.0 - 12.4 Nm) |
Primary/ transmission lubricant level screw62)63) | 90 - 110 in. lbs (10.2 - 12.4 Nm) |
Chain tensioner stud nut64)65) | 20 - 25 ft lbs (27 - 34 Nm) |
Stator Torx fasteners66)67) | 30 - 40 in. lbs (3.4 - 4.5 Nm) |
Neutral indicator switch (91-92)68) | 3 -5 ft lbs |
Shift lever pinch bolt69)70) | 90 - 110 in lbs (10.2 - 12.4 Nm) |
Footrest fasteners71)72) | 16 - 28 ft lbs (22 - 38 Nm) |
Clutch release mechanism screws73)74) | 22 - 30 in lbs (2.5 - 3.4 Nm) |
Inspection (Derby) cover screws75)76) | 40 - 60 in lbs (4.5 - 6.8 Nm) |
Countershaft retaining screw77)78) | 13 - 17 in lbs (18 - 23 Nm) |
Sprocket nut lock-plate screws79) | 90-110 in-lbs / 10.2-12.4 Nm |
Sprocket nut (caution - left handed threads)80) 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 screws81) | 90-110 in-lbs. (10.2-12.4 Nm) |
Access / trapdoor bolts82) | 13-17 ft-lbs. (18-23 Nm) |
Engine sprocket nut83) | 190-210 ft-lbs. (258-285 Nm) |
Clutch hub nut (caution- left hand threads)84) | 70-80 ft-lbs (95-108 Nm) |
Countershaft retaining screw85) | 13-17 ft-lbs (18-23 Nm) |
Oil Drain plug86) | 14-21 ft-lbs. (19-28 Nm) |
Primary cover Allen Head screws (1/4“x 20 threads)87) | 80-110 in-lbs. (9.0-12.4 Nm) |
Primary chain tensioner stud88) | 20-25 ft-lbs. (27-34 Nm) |
Stator Torx Head screws(1/4”x 20 threads)89) | 30-40 in-lbs. (3.4-4.5 Nm) |
Shift lever pinch bolt90) | 90-110 in-lbs. (10.2-12.4 Nm) |
Clutch inspection (Derby)cover T-27 Torx Head screws91) | 40-60 in-lbs. (4.5-6.8 Nm) |
Footrest Allen Head bolts (5/16“x18)92) | 16-28 ft-lbs. (22-38 Nm) |