IH: Transmission & Final Drive

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====== IH: Transmission & Final Drive ======
^Click here for tips on [[techtalk:ref:svcproc10#speed_transmission_removal_inspection_installation|4 Speed Transmission Removal / Inspection / Installation]]^  
====== 1957 - 1970 Sportster Four-Speed Constant Mesh Dry Clutch Transmission Specifications ======

===== Clutch =====

===== Sub-Documents =====
* . . . [[techtalk:ih:transfinal02a|How to Adjust a Dry Clutch]] \\ 




----



  * Type:
    * Dry - Multiple disc
      * Worth noting is the MoCo had an optional wet clutch kit for 1954-up KH, XL, XLH, XLCH models. Kit # (37984-57)
    * 7 friction plates, 7 steel plates between a steel backing plate and a front releasing disc 
    *Back to front: Backing plate-S-F-S-F-S-F-S-F-S-F-S-F-S-F-Releasing disc
  * Capacity: 1900 in-lbs. (158.33 ft lbs.) 
  * Set up Spring Pressure: 150 lbs.
    * Spring adjustment: 3/16 in. from inner surface of spring tension adjusting plate to outer surface of spring cup flange
  * Clutch bearing: .0005 - .002 in. loose
  * (1970) - .0005 - .0029 in. loose
  * Clutch cover: Must be leak proof. No gasket sealer
  * Clutch release rod movement: .095 - .115 in.


==== Adjusting Clutch Release Mechanism ====
  * Loosen clutch release rod adjusting screw lock nut and rod adjusting screw. Clutch release worm (inside the sprocket cover) should seat against it's stop when clutch handle is fully extended. If lever doesn't fully seat, check for cable binding in housing.
  * Adjust cable length by turning the adjusting sleeve (at hand lever) so the clutch release worm does not quite return against it's stop. This will hold the hand lever in it's fully extended position at all times. 
  * Tighten clutch release rod adjusting screw until hand lever has 1/8 in. free play before clutch starts to release (slight tension).
  * Tighten locknut without disturbing the current cable setting.   




===== 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 (7/16”x14x1-1/8”), 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 (9220A) with an oversized pair (+0.001 - 9225A), (+0.002 - 9227A) or (+0.003 -  9229A). ((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 (34514-52) 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^
|Standard|1966 & Earlier XLCH \\ 1967 & later XLH, XLCH|34 Teeth|59 Teeth|
|Optional|1966 and Earlier XL, XLH \\ 1967 XLH, XLCH|34 Teeth|59 Teeth|

**Clutch Sprocket Assembly**
  * Late 1957-1966 XL, XLH, XLCH (37702-57) ((HD Sportster Parts catalog 99451-78B))
  * 1967-1969 XLCH  (37702-57) ((HD Sportster Parts catalog 99451-78B))
  * 1967-1970 XLH (37700-67) ((HD Sportster Parts catalog 99451-78B))
  * 1970 XLCH (37701-70)((HD Sportster Parts catalog 99451-78B))



**Primary Chain**
  *Type primary: 3/8 in. pitch triple chain
  *Looseness: 5/8 to 7/8 in. slack (cold engine) - 3/8 to 5/8 in. slack (hot engine)

===== Kick Starter =====
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.

  * Minimum clearance between clutch teeth on starter clutch gear and clutch with starter in up position: .040 in.
  * Crankshaft endplay: .001 - .007 in.


===== Electric Start =====
On 1967 and later model XLH, an electric starter motor and Bendix type drive unit engage the ring gear on the clutch to crank the engine.
===== Gear Shifter =====
  * 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. 
  * 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.
===== Transmission =====

    * Overall Gear Ratios are the number of engine revolutions to drive rear wheel one revolution. 

^  ^    ^Overall Gear Ratios^^^^
^  ^Year Models|1st|2nd|3rd|4th|
|Standard|1966 & Earlier XLCH \\ 1967 & Later XLH, XLCH|11.16:1|8.08:1|6.11:1|4.42:1|
|Optional|1966 & Earlier XL, XLH \\ 1967 XLH, XLCH|10.63:1|7.69:1|5.82:1|4.21:1|

**Transmission Oil Capacity** ((1959-1969 HD Sportster FSM pg 1A-3)) ((1970-1978 HD Sportster FSM pg 1-1)): **1.5 pints / (24 oz) / (710 ml)** 


===== Final Drive (Trans to Wheel) =====


|Standard Year Model ((HD Spare Parts Catalog for all Sportster and K Models pg 30)) ((1953-1963 HD Sportster and KH Models Parts Catalog pg 38)) ((1961-1971 HD Sportster Parts Catalog pg 41)) ((1954-1976 HD Sportster Parts Catalog g 57)) ((1954-1978 HD Sportster Parts Catalog pg 75)) ((1979-1985 HD Sportster Parts Catalog pg 61)) ((1986-1990 HD Sportster Parts Catalog pg 45))|Part #|Transmission Sprocket:  \\ (All with a 51 Tooth Rear Wheel Sprocket)|
^XL^ ^^
|E1957|35205-52|21 Tooth|
|L1957-1959|35205-52A|:::|
^XLC^ ^^
|1958|35205-52A|21 Tooth|
^XLH^ ^^
|1958 - E1967|35205-52A|21 Tooth|
|L1967-1973|35198-52|20 Tooth ((1970-1978 Sportster FSM pg 1-1))|
|1973-E1979|35205-52A|21 Tooth ((1970-1978 Sportster FSM pg 1-1))|
^XLCH^ ^^
|1958|35205-52A|21 Tooth|
|1959-E1969 XLCH|35198-52|20 Teeth|
|L1969-1971 ((1970-1978 Sportster FSM pg 1-1)) \\ (Engine # 69XLCH 5921 →) ((HD Service Bulletin #455 dated 12-6-1961))|35197-52|19 Tooth|
|1972-1973|35198-52|20 Tooth ((1970-1978 Sportster FSM pg 1-1))|
|1973-E1979 ((1970-1978 Sportster FSM pg 1-1)) ((1954-1978 HD Sportster Parts Catalog pg 75)) ((1979-1985 HD Sportster Parts Catalog pg 61))|35205-52A ((1979-1985 HD Sportster Parts Catalog pg 61))|21 Tooth ((1970-1978 Sportster FSM pg 1-1))|
|L1979|35208-79A|21 Tooth|
^XL/XLS/XLX^ ^^
|L1979-E1984|35208-79A|21 Tooth|
|L1984-1990|35208-84|21 Tooth|


  * By the time the 1976 parts catalog came out, all three early transmission sprocket versions were available for replacement of the original no matter which bike you had and from 1954 to then current. It stayed that way until Late 1979 in the parts catalogs. However, 1973 and up Sportsters all came factory with a 21T sprocket, according to the FSM. There is also an overlap in 1973 in that the FSM(s) states a 21T and a 20T for 1973 ((The Doctor71 of the XLFORUM)). Maybe a mid year change?


----


===== Torque Specs =====

|Clutch Hub Nut|150 ft lbs|
===== Mainshaft Group =====
  *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: .004 - .009 in.
  *(1970) .003 - .009 in. with all axial play removed
  *Third gear
    * On shaft: .002 - .003 in. loose
    * End play: .015 - .025 in. loose
    * (1970) .012 - .030 in


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




|**1956-1966 KH** (engine #1465 →) **XL/XLH/XLCH** \\ **1967-1969 XLCH** ((HD Spare Parts Catalog for all Sportster and K Models 1952-1959 pg 31)) |||
|:::|Clutch Gear|37450-56 \\ replaced by \\ 37449-56|
|:::|Clutch Gear Washer|35361-56|
|:::|Needle Bearings (2)|35960-54 (closed end) \\ replaced by \\ 35961-52 (open end)|
|:::|Clutch Gear Bushing|37458-52|
|:::|Drive Sprocket 21T  ((1957-1967 HD Sportster and KH Model Parts Catalog pg 39)) \\ 1952-1953 K/KK \\ 1954-1955 KH (engine #1689 →) ((HD Spare Parts Catalog for all Sportster and K Models pg 30)) \\ 1957-1959 XL \\ 1958-E1967 XLH \\ 1958-1971 XLCH (except 1959)|35205-52 \\ replaced by \\ 35205-52A|
|:::|Drive Sprocket 20T ((1957-1967 HD Sportster and KH Model Parts Catalog pg 39)) ((1959-1969 Sportster and KH Model Parts Catalog)) ((1952-1959 HD Spare Parts Catalog pg 35)) ((1953-1963 HD Parts Catalog for Sportsters and K Models pg 38)) ((1961-1971 HD Sportster Parts Catalog pg 41)) \\ 1959-1971 XLCH \\ L1967-1971 XLH|35198-52|
|:::|Drive Sprocket 19T ((1953-1963 HD Parts Catalog for Sportsters and K Models pg 38)) ((1961-1971 HD Sportster Parts Catalog pg 41)) \\ 1953-1956 K/KH \\ L1969 XLCH (engine #69XLCH-5921 →)|35197-52|
|**1967-1970 XLH** \\ **1970 XLCH**|||
|:::|Clutch Gear|37448-67|
|:::|Clutch Gear Washer|35361-56|
|:::|Needle Bearings (2)|35961-52|
|:::|Clutch Gear Bushing|37458-52|
|:::|Drive Sprocket 21T ((1954-1976 HD Sportster Parts Catalog pg 57)) \\ XLH/XLCH|35205-52A|
|:::|Drive Sprocket 20T ((1954-1976 HD Sportster Parts Catalog pg 57)) \\  XLH/XLCH|35198-52|
|:::|Drive Sprocket 19T ((1954-1976 HD Sportster Parts Catalog pg 57)) \\ XLH/XLCH|35197-52|


==== 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))^
|**L1956 KH** (engine # 1465 →) \\ **1957-1966 XL/XLH/XLCH** \\ **1967-1969 XLCH**|35044-56|1957|  |
|**1967-1970 XLH** \\ **1970 XLCH**|35046-67|1967 \\ 1970|
^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** \\ **1957-1965** \\ **XL/XLH/XLCH**|35269-56 (23T)|1957|  |
|**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)) |

=== Mainshaft roller bearings ===
Standard rollers should measure .15625"-.15610". ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1601769&page=2)) \\
Fit to shaft may not be determined by race size. \\
In order to fit 23 new std rollers in the race, it needs to be big enough to accept 23 rollers with out the rollers binding in the race. \\
When sized to the min. dia. that accepts 23 rollers with out bind, the shaft (.991" dia) will be will be about .002 running clearance. \\
This is because there is no roller cage. The rollers touch each other. \\
Because of the zero% roller to roller space trying to fit 23 o.s. rollers means the race needs to a lot bigger than the roller amount of roller o.s. \\
This results in a looser running fit than used in the standard rollers. \\
To use the os rollers and get a tighter fit than 23 standards, you can only use 22 o.s rollers. \\
Rigid hone / line lap race to take 23 standards. \\ Then let clearance be whatever it is. \\

|  Mainshaft roller bearings ((photo by lynx of the XLFORUM http://xlforum.net/forums/showthread.php?t=2070971&highlight=oil+filter&page=10))  |
|{{:techtalk:ih:transfinal:1960_mainshaft_roller_bearings_by_lynnx.jpg?direct&400|}}|

===== Countershaft Group =====
  *Countershaft end bearings: Retained needle roller bearing
  *Bearing fit on shaft ends: .0005 - .002 in. loose
  *Bearing fit in case: press
  *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.
  * Drive gear
    * On shaft: .001 - .0025 in. loose
    * (1970) .0005 - .0030 in. loose
    * End play: .004 - .009 in.
  * Clearance between clutch faces
    * Countershaft low an third gear: .038 - .058 in.      
    * Countershaft second and third gear: .038 - .058 in.      
    * 1970
      * Mainshaft clutch gear and second gear: .043 - .083 in. 
      * Mainshaft third gear and second gear: .043 - .083 in.
      * Shifter end play: .010 - .030 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))^^
|**1954-1956 KH** \\ **1957 XL**|35613-54|[[techtalk:ih:transfinal03#countershaft_and_oiler_plug|More information about countershafts and the oiler plug]]||
|**1958-E1984** \\ **All**|35613-58|:::||
^Countershaft Drive Gear^Part No.^Change Year^Notes^
|**1952-1956 K** (all) \\ **1957 XL**|35695-52 (29T)|-|
|**1952-1956 K** (all) \\ **1957 XL**|35695-52A (27T)|-|
|**1958-1985** \\ **XL/XLC/XLH/XLCH/XLS**|35695-58 (27T)|1958|
^Countershaft 2nd Gear^Part No.^Change Year^Notes^
|**1954-1956 KH**|35750-54B (21T)|-|
|**1954-1956 KH** \\ **1957 XL** \\ (replacement part)|35750-54C (21T)|1957|
|**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**|35709-54 (24T) ((1952-1957 HD Spare Parts Catalog for Sportster and K Models pg 25))|-|
|**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^
|**1954-1956 KH**|35759-54 (17T)|-|
|**1957-Early 1966** \\ **XL/XLC/XLH/XLCH**|35760-54 (17T)|1957|Single counter-bore (case side) allowing gear to slip over the right case casting boss. \\ Cannot be used on Late '66 and later right case with added fillet at the base of the gear boss.|
|**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)| 



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