TRANSMISSION
This chapter covers the five-speed transmission for the 1991-2003 models, internal gearshift assemblies and shift mechanism.
When the clutch is engaged, the mainshaft is driven by the clutch hub, which is driven by the primary chain sprocket/clutch outer housing. Power flows from the mainshaft through the selected gear combination to the countershaft, which drives the main drive gear and transmission sprocket. To gain access to the transmission and internal shift mechanism, it is not necessary to remove the engine or disassemble the crankcase. The transmission components are contained behind an access door on the left crankcase half.
Years Covered in this Sportster Service Repair Manual: XLH883 (1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2001, 2002 and 2003 models), XLH883 CUSTOM (1999, 2000, 2001 and 2003 models), XLH883 DELUXE (1991, 1992, 1993, 1994 and 1995 models), XLH883 HUGGER (1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL883R (2002-2003 models), XLH1200 (1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 CUSTOM (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL1200 SPORT (1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003 models), XL XLH 883, 1200 and 1200.
Removal
1. Remove the exhaust system and drain the transmission oil. Remove the drive sprocket and drive chain or belt. Remove the engine sprocket, clutch and primary drive chain and shift the transmission into first gear.
Inspection
1. Clean the transmission cavity
with cleaning solvent and dry with compressed air. Inspect the access door bearings as described in the service manual. Remove all thread sealant residue from the drive sprocket nut and main drive gear threads.
1. If the shift forks, shift drum and transmission were removed and disassembled, assemble them onto the access door as described in the service manual.
If removed, install the main drive gear as described in your service manual. Lubricate the transmission gears and shifter assembly with new transmission oil prior to installation and install the two dowel pins, if removed.
1. Remove the transmission assembly as described in your service manual and s
ecure the transmission access door in a vise with soft jaws. Then remove the following parts:
b. Reinforcing plate.
c. Detent screw, arm and spring.
d. Shift drum locating plate.
3. Remove the cotter pin
from each shift fork and discard the cotter pins.
4. Remove the shift fork pin from each shift fork.
MAINSHAFT AND COUNTERSHAFT
1. Remove the transmission as described in your repair manual and remove the shift forks and shift drum as described.
3. Clamp the transmission in a vise with soft jaws. The transmission shafts are identified as follows: b. Mainshaft. positioned next to countershaft fifth gear and remove the following gears in order: b. Mainshaft second gearc. Countershaft second gear.
MAIN DRIVE GEAR
Two tools are required to remove and install the main drive gear located in the right crankcase half. Removing the main drive gear without these tools, may cause crankcase and/or main drive gear damage.
Main Drive Gear Installation
1. Replace the main drive gear bearing
as described in Right Transmission Case Bearings
RIGHT TRANSMISSION CASE BEARINGS
The right transmission case is equipped with the following bearings:
1. Main drive gear bearing
2. Countershaft needle bearing
3. Shift drum needle bearing
Each of these bearings can be replaced with the engine crankcase assembled and installed in the frame.
SHIFT MECHANISM
To inspect and service the shift shaft assembly, the transmission must be disassembled as described in this chapter. The shift lever can be removed by loosening the pinch bolt. Tighten the pinch bolt to 90-110 in.-lb. (10-12 N•m).
Transmission Parts
1. Drive sprocket
2. Oil seal
3. Spacer (drive belt)
4. Quad ring
5. Snap ring
6. Bearing
7. Right crankcase half
8. Seal
9. Needle bearing
10. Main drive gear
11. Needle bearing
12. Mainshaft second gear
13. Snap ring
14. Thrust washer
15. Mainshaft third gear
16. Split bearing
17. Mainshaft first gear
18. Mainshaft fourth gear
19. Spacer
20. Mainshaft
21. Access door
22. Bushing
23. Bearing
24. Snap ring
25. Spring washer
26. Mainshaft nut
27. Countershaft needle bearing
28. Shift shaft needle bearing
29. Countershaft fifth gear
30. Countershaft second gear
31. Countershaft third gear
32. Countershaft
33. Countershaft first gear
34. Countershaft fourth gear
35. Beveled washer
36. Bearing
37. Snap ring
38. Retainer collar
39. Screw
Shift Assembly Parts
in you repair manual and coat the oil seal lips with transmission oil prior to installation. Slide the oil seal, with its lips facing toward the crankcase, over the spacer. Tap the oil seal into the crankcase until its outer surface is flush with or slightly below (0.030 in. [0.76 mm] maximum) the oil seal bore inside surface. Insert the main drive gear into the main drive gear bearing in the transmission portion of the engine crankcase as far as it will go. Then hold it in place and assemble the main drive gear remover and installer tool as shown in your reference manual.
a. Countershaft.
a. Countershaft fifth gear
Disassembly
a. Detent nut and washer.
SHIFT FORKS AND SHIFT DRUM
Disassembly
Installation
1. Shift shaft assembly
2. Locknut
3. Washer
4. Right crankcase half
5. Detent plate snap ring
6. Detent plate
7. Detent screw
8. Spring
9. Detent arm
10. Shifter drum locating plate
11. Reinforcing plate
12. Washer
13. Locknut
14. Countershaft bearing
15. Mainshaft bearing
16. 4th gear shift fork
17. Shift fork pins
18. Cotter pins
19. 1st and 2nd gear shift fork
20. 3rd and 5th gear shift fork
21. Shift drum
22. Pin (neutral indicator)
23. Access door
Main Drive Gear Parts Assembly
1. Drive sprocket
2. Oil seal
3. Spacer (drive belt)
4. Quad ring
5. Snap ring
6. Bearing
7. Right crankcase half
8. Seal
9. Needle bearing
10. Main drive bearing (fifth gear)
