Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

c. Disconnect the pawl spring (Figure 65) and remove

the pawl (Figure 66).

d. Repeat for the opposite pawl.

9. Inspect the shift mechanism as described in this section.

10. Assembly is the reverse of disassembly, noting the fol-
lowing.

a. Install pawls on the pawl carrier, using spacers so that

the spring hook holes align. Note that one spacer will
be underneath the pawl and the other spacer will be
on outside of the pawl. See 26 and 31, Figure 57. Re-
tract one pawl. at a time, then install the shifter cam
into pawl carrier.

b. Install the assembly into the pawl carrier support so

that the ear of the pawl is between the ends of the
pawl carrier springs.

c. Install a new E-clip and washer.
d. Make sure that the pawls engage the cam ratchet.

Inspection

1. Clean all parts in solvent, then blow dry.
2. Examine the shifter cam for worn or grooved cam slots
(A, Figure 67). Excessive wear will result in difficult shift-
ing.
3. Check the shifter cam gear (B, Figure 67) for wear or
damage.
4. Examine the pawl carrier yoke (Figure 68) where it en-
gages the lever arm shaft. A severely worn yoke will cause
the transmission to jump out of gear.

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

299

Table 1 TRANSMISSION SERVICE SPECIFICATIONS

New

Service Limit

in. (mm)

Clutch face clearance

Mainshaft 4th and 2nd gear

0.040

0.080

(1.02)

(2.03)

Mainshaft 3rd and 2nd gear

0.040

0.080

(1.02)

(2.03)

Clutch gear needle bearing journal diameter

0.7495-0.7500

0.7485

(19.037-19.050)

(19.012)

Countershaft

Needle bearing journal diameter

Access door

0.7500-0.7495

0.7490

(19.050-19.037)

(19.025)

Right crankcase side or end

0.6875-0.6870

0.6865

(17.463-17.450)

(17.437)

Countershaft end play

0.004

0.015

(0.10)

(0.38)

1st gear needle bearing journal diameter

0.6875-0.6870

0.6865

(17.463-17.450)

(17.437)

Gear face clearance

Countershaft 1st and 3rd gear

0.040

0.080

(1.02)

(2.03)

Countershaft 2nd and 3rd gear

0.040

0.080

(1.02)

(2.03)

Mainshaft end play

0.006

0.020

(0.15)

(0.51)

Mainshaft 3rd gear end play

0.006-0.020
(0.15-0.51)

Mainshaft and countershaft runout

–

0.003
(0.08)

Table 2 EARLY AND LATE STYLE GEAR OUTSIDE DIAMETERS

Outside diameter

Gear

Number or teeth

in. (mm)

Early style gears

Countershaft 2nd gear

2.448-2.452
(62.18-62.28)

Countershaft 3rd gear

2.648-2.657
(67.26-67.49)

Mainshaft 2nd gear

2.648-2.657
(67.26-67.49)

Mainshaft 3rd gear

2.448-2.452
(62.18-62.28)

Late style gears

Countershaft 2nd gear

2.423-2.428
(61.54-61.67)

Countershaft 3rd gear

2.622-2.627
(66.60-66.73)

Mainshaft 2nd gear

2.622-2.627
(66.60-66.73)

Mainshaft 3rd gear

2.423-2.428
(61.54-61.67)

Table 3 GEAR RATIOS

1986 models

1987-1990 models

Internal gear ratios

1st

2.52

2.29

2nd

1.82

1.66

3rd

1.38

1.25

4th

1.00

(continued)

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

301

Table 3 GEAR RATIOS (continued)

1986 models

1987-1990 models

Overall gear ratios

1st

10.00

9.12

2nd

7.25

6.59

3rd

5.48

4.98

4th

3.97

Table 4 COUNTERSHAFT GEAR SPACER SELECTION CHART

Measurement

Number of

(in.)

washers

Part No.

0.335-0.339

35860-86

0.330-0.334

35865-86

0.325-0.329

35865-86

35864-86

0.320-0.324

35865-86

35863-86

0.315-0.319

35864-86

35863-86

0.310-0.314

35863-86

0.305-0.309

35863-86

35862-86

0.300-0.304

35863-86

35861-86

0.295-0.299

35862-86

35861-86

0.290-0.294

35861-86

0.285-0.289

35861-86

35860-86

0.280-0.284

35860-86

0.275-0.279

35864-86

35863-86

0.270-0.274

35863-86

0.265-0.269

35863-86

35862-86

0.260-0.264

35863-86

35862-86

0.255-0.259

35864-86

35861-86

0.250-0.254

35863-86

35861-86

0.245-0.249

35862-86

35861-86

0.240-0.244

35861-86

0.235-0.239

35861-86

35860-86

Table 5 COUNTERSHAFT WASHERS

Thickness

Part No.

0.055 in.

35860-86

0.050 in.

35861-86

0.045 in.

35862-86

0.040 in.

35863-86

0.035 in.

35864-86

0.030 in.

35865-86

302

CHAPTER EIGHT

Table 6 MAINSHAFT END PLAY THRUST WASHER SELECTION

End play

Washer thickness

Part No.

0.114-0.108 in.

0.099-0.094 in.

35380-84

0.107-0.102 in.

0.093-0.088 in.

35381-84

0.101-0.097 in.

0.087-0.082 in.

35382-84

0.096-0.092 in.

0.082-0.077 in.

35383-84

0.091-0.086 in.

0.081-0.070 in.

35384-84

0.085-0.079 in.

0.070-0.065 in.

35385-84

Table 7 COUNTERSHAFT END PLAY THRUST WASHER SELECTION

Measurement

Number of

(in.)

washers

Part No.

0.172-0.176

35860-86

0.167-0.171

35861-86

35860-86

0.162-0.166

35860-86

35861-86

0.157-0.161

35861-86

0.152-0.156

35862-86

35861-86

0.147-0.151

35862-86

35861-86

0.142-0.146

35862-86

0.137-0.141

35863-86

35862-86

0.132-0.136

35863-86

35862-86

0.127-0.131

35863-86

0.122-0.126

35864-86

35863-86

0.117-0.121

35860-86

0.112-0.116

35861-86

35860-86

0.107-0.111

35861-86

0.102-0.106

35862-86

35861-86

0.097-0.101

35862-86

0.092-0.096

35863-86

35862-86

0.087-0.091

35863-86

0.082-0.086

35863-86

35864-86

0.077-0.081

35864-86

0.072-0.076

35865-86

35864-86

0.067-0.071

35865-86

0.062-0.066

35860-86

0.057-0.061

35861-86

0.052-0.056

35862-86

0.047-0.051

35863-86

0.042-0.046

35864-86

Table 8 TRANSMISSION TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Transmission access door bolts

14-19

–

19-26

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

303

CHAPTER NINE

FIVE-SPEED TRANSMISSION

(1991-2003 MODELS)

This chapter covers the five-speed transmission, internal

gearshift assemblies and shift mechanism. Tables 1 and Ta-
ble 2 are at the end of this chapter.

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 trans-
mission 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.

TRANSMISSION

Removal

Refer to Figure 1.

1. Remove the exhaust system (Chapter Eleven).
2. Drain the transmission oil (Chapter Three).
3. Remove the drive sprocket and drive chain or belt
(Chapter Thirteen).
4. Remove the engine sprocket, clutch and primary drive
chain (Chapter Eight).
5. Shift the transmission into first gear.

6. Disconnect the detent lever spring (Figure 2) from the
post groove.

7. Remove the snap ring (A, Figure 3) from the groove in
the end of the shift drum. Discard the snap ring as a new one
must be installed during reassembly.

8. Slide the detent plate (B, Figure 3) off the shift drum
pins.

9. Loosen the two shift shaft locknuts (A, Figure 4). Then
remove the locknuts and washers.

10. Remove the shift shaft assembly (B, Figure 4) from the
crankcase.

11. Remove the countershaft retainer screw (Figure 5).
Then remove the screw and countershaft retainer collar
(Figure 6).

12. Remove the transmission access door mounting bolts
(Figure 7).

13. Remove the access door with the transmission and shift
mechanism attached. See Figure 8.

14. Remove the two dowel pins (Figure 9).

15. If further disassembly is necessary, perform the fol-
lowing as described in this chapter:

Shift Forks and Shift Drum.

Mainshaft and Countershaft

16. If necessary, remove the main drive gear as described
in

Main Drive Gear

in this chapter.

Inspection

1. Clean the transmission cavity (Figure 9) with cleaning
solvent and dry with compressed air.
2. Inspect the access door bearings as described in this
chapter.
3. Remove all thread sealant residue from the drive
sprocket nut and main drive gear threads.

Installation

A No. 32 (0.116 in.) drill bit will be required when in-

stalling the transmission assembly.

Refer to Figure 1.

1. If the shift forks, shift drum and transmission were re-
moved and disassembled, assemble them onto the access
door as described in the following sections in this chapter:

Mainshaft and Countershaft

Shift Forks and Shift Drum Assembly

2. If removed, install the main drive gear as described in

Main Drive Gear

in this chapter.

3. Lubricate the transmission gears and shifter assembly
with new transmission oil prior to installation.
4. Install the two dowel pins (Figure 9), if removed.
5. Align the transmission assembly with the access door
opening and install the transmission/shifter assembly (Fig-
ure 8) while noting the following:

306

CHAPTER NINE

a. The mainshaft (Figure 10) should enter fifth gear

(Figure 11).

b. The drum shift shaft and countershaft should enter

their respective crankcase bearings.

6. Apply threadlock (Loctite 242 or eqivalent) to the trans-
mission access door mounting bolts prior to installation. In-
stall the bolts (Figure 7) and washers and tighten to
156-204 in.-lb. (18-23 N•m).
7. Install the countershaft retainer collar (Figure 5) as fol-
lows:

a. The retainer collar has one flat side and one beveled

side.

b. Install the retainer collar, with its beveled side facing

out, onto the countershaft (Figure 6).

c. Shift the transmission into first gear.
d. Apply threadlock (Loctite 242 or equivalent) onto the

retainer collar screw prior to installation. Install the
countershaft retainer collar screw and tighten to
156-204 in.-lb. (18-23 N•m).

8. Install the shift shaft assembly by first lifting the shift
pawl (Figure 12) over the shift drum pins and then aligning
the shift shaft mounting holes with the two crankcase studs
(A, Figure 4). Install the washers and nuts (A, Figure 4);
hand tighten the nuts only.
9. Connect the detent arm spring onto the post groove as
shown in Figure 2.
10. Make sure the shift pawl spring is connected to the
pawl (Figure 13).
11. Install the detent plate onto the shift drum, aligning the
holes in the plate with the pins in the drum (Figure 14).
12. Install a new detent plate snap ring (Figure 15) into the
groove in the end of the shift drum. Use the installation tool
(TRUARC part No. PR-0310 or equivalent) to install the
new snap ring. Make sure the snap ring is correctly seated
in the shift drum groove.
13. Adjust the shifter pawl as follows:

a. Shift the transmission into third gear.
b. Install a No. 32 drill bit (0.116 in.) through the hole in

the detent plate and between the shift pawl and drive
pin at the end of the shift drum shaft as shown in Fig-
ure 12 and A, Figure 16.

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)

307

SHIFT SHAFT

Nut

Crank

Pawl

Detent plate

No. 32 drill bit (0.116 in. dia.)

Pawl

Shifter drum pin

Drill bit

NOTE

Pressing down on the shift shaft crank helps
to align the shift pawl with the shift drum
pins. However, do not push excessively as this
may cause the shift drum to rotate.

c. Press down on the top of the shift shaft crank (Figure

12) to remove all clearance between the drill bit and
shift pawl.

d. While applying pressure to the shift shaft crank,

tighten the lower shift shaft locknut (B, Figure 16) to
90-110 in.-lb. (10-12 N

•

m).

e. Tighten the upper shift shaft nut (C, Figure 16) to

90-110 in.-lb. (10-12 N•m).

f. Remove the drill bit.

14. Install the engine sprocket, clutch and primary drive
chain (Chapter Eight).
15. Refill the transmission oil (Chapter Three).
16. Install the drive sprocket and the drive chain or drive
belt (Chapter Thirteen).
17. Install the exhaust system (Chapter Eleven).
18. Start the engine and check for oil leaks.
19. Test drive the motorcycle slowly, checking that the
transmission shifts properly.

SHIFT FORKS AND SHIFT DRUM

Disassembly

Refer to Figure 1.

1. Remove the transmission assembly as described in

Transmission

in this chapter.

2. Secure the transmission access door in a vise with soft
jaws. Then remove the following parts:

a. Detent nut and washer (A, Figure 17).
b. Reinforcing plate (B, Figure 17).
c. Detent screw, arm and spring (C, Figure 17).
d. Shift drum locating plate (Figure 18).

3. Remove the cotter pin (Figure 19) from each shift fork.
Discard the cotter pins.
4. Remove the shift fork pin from each shift fork (Figure
20).

308

CHAPTER NINE

5. Slide the shift drum (Figure 21) out of the access door
and remove it.
6. Remove the three shift forks (Figure 22).

Inspection

1. Clean all of the parts in solvent, except the access door
bearings, and dry with compressed air.
2. Inspect each shift fork (Figure 23) for severe wear,
cracks, bending or other damage. Check that each shift fork
slides on the shift drum smoothly (Figure 24).
3. Check for any arc-shaped wear or burned marks on the
shift forks. This wear pattern indicates that the shift fork
has come in contact with the gear. The fork fingers have be-
come excessively worn and the fork must be replaced.
4. Check the shift drum grooves (A, Figure 25) for wear or
roughness. If any groove profile shows excessive wear or
damage, replace the shift drum.
5. Check the shift drum pins (Figure 26) for cracks or se-
vere wear.
6. Check the shift fork pins for cracks or severe wear.
7. Roll the shift drum on a flat surface, such as a piece of
plate glass, and check it for any warp or damage.
8. Inspect the shift shaft assembly (Figure 27) for the fol-
lowing defects:

a. Bent shift shaft (A, Figure 27).
b. Damaged shift shaft splines (B, Figure 27).

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)

309

c. Worn or damaged shift pawl (Figure 28).
d. Weak or damaged return springs.

9. Inspect the detent arm assembly (Figure 29) for the fol-
lowing defects:

a. Worn or damaged detent screw (A, Figure 29).
b. Worn or damaged detent arm (B, Figure 29).
c. Worn or damaged shift drum locating plate (C, Fig-

ure 29).

d. Worn or damaged reinforcing plate (D, Figure 29).

10. Check the detent plate (Figure 30) for severe wear or
damage.
11. Refer to

Access Door Bearings

in this chapter to clean,

inspect and replace bearings.
12. Replace worn or damaged parts as required.

Assembly

Refer to Figure 1.

1. Clamp the transmission access door in a vise with soft
jaws.
2. Lubricate each shift fork bore with new transmission oil
prior to installation.

NOTE

Refer to

Figure 31

when identifying and in-

stalling the shift forks.

3. Install shift fork No. 1 (third and fifth gear), with its flat
side facing toward the access door, into the mainshaft sec-
ond gear groove (A, Figure 32).
4. Install shift fork No. 2 (first and second gear), with its
flat side facing away from the access door, into the
countershaft third gear groove (B, Figure 32).
5. Install shift fork No. 3 (fourth gear), with its flat side
facing away from the access door, into the mainshaft first
gear groove (C, Figure 32).
6. Align the shift drum, with its neutral indicator pin (B,
Figure 25) facing up, with the shift forks. Then insert the
shift drum (Figure 21) through the shift forks and the bear-
ing in the access door.
7. Lubricate the shift fork pins with new transmission oil
prior to installation.

310

CHAPTER NINE

CAUTION

The cotter pins must be installed through the
shift forks as shown in

Figure 33

. Otherwise,

the cotter pins may be damaged during trans-
mission operation.

8. Align the lower shift drum groove (A, Figure 34) with
the pin hole in shift fork No. 3 (fourth gear); refer to C, Fig-
ure 32. Install the shift fork pin through the shift fork so it
drops into the shift drum groove; turn the shift drum while
pushing on the pin with a small screwdriver. Then install a
new cotter pin.

9. Align the center shift drum groove (B, Figure 34) with
the pin hole in shift fork No. 2 (first and second gear); refer
to B, Figure 32. Install the shift fork pin through the shift
fork so it drops into the shift drum groove; turn the shift
drum while pushing on the pin with a small screwdriver.
Then install a new cotter pin.

10. Align the upper shift drum groove (C, Figure 34) with
the pin hole in shift fork No. 1 (third and fifth gear); refer to
A, Figure 32. Install the shift fork pin through the shift fork
so it drops into the shift drum groove; turn the shift drum
while pushing on the pin with a small screwdriver. Then in-
stall a new cotter pin.

NOTE

Refer to

Figure 33

and

Figure 35

for the cor-

rect installation of the shift fork cotter pins.

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)

311

Shift fork 3

4th gear

Shift fork 2

1st and 2nd gear

Shift fork 1

3rd and 5th gear

Cotter pins

11. Install the shift drum locating plate (Figure 36) into the
shift drum groove, making sure the hole in the plate fits
over the roll pin in the access door (Figure 37).
12. Install the reinforcing plate (A, Figure 38) on top of
the shift drum locating plate, making sure to engage the
notch in the reinforcing plate with the roll pin in the access
door.
13. Slide the detent screw (A, Figure 39) through the
detent arm (B, Figure 39). Then insert the detent screw
through the access door and through the two plates previ-
ously installed; see Figure 38. Install the washer and nut
(B, Figure 39). Tighten the detent screw to 156-204 in.-lb.
(18-23 N•m).

NOTE

Do not install the detent plate (6,

Figure 1

)

and snap ring (5) at this time. These parts are
installed during transmission installation
and shift pawl adjustment.

14. Install the transmission as described in this chapter.

MAINSHAFT AND COUNTERSHAFT

Refer to Figure 40.

Disassembly

NOTE

Identify and store all parts as they are disas-
sembled so they will be installed in their same
locations.

1. Remove the transmission as described in this chapter.
2. Remove the shift forks and shift drum as described in
this chapter.
3. Clamp the transmission in a vise with soft jaws as shown
in Figure 41. The transmission shafts are identified as fol-
lows:

a. Countershaft (A, Figure 41).
b. Mainshaft (B, Figure 41).

4. Remove the snap ring (Figure 42) positioned next to
countershaft fifth gear.
5. Remove the following gears in order:

a. Countershaft fifth gear (Figure 43).
b. Mainshaft second gear (Figure 44).
c. Countershaft second gear (Figure 45).

6. Remove the countershaft second gear split bearing (Fig-
ure 46).
7. Remove the countershaft thrust washer (A, Figure 47).
8. Remove the snap ring (B, Figure 47) positioned next to
countershaft third gear.
9. Remove countershaft third gear (Figure 48).
10. Remove the snap ring (Figure 49) and thrust washer
located next to mainshaft third gear. See Figure 50.
11. Remove the mainshaft third gear (Figure 51).

12. Remove the mainshaft third gear split bearing (Figure
52).

13. Remove the mainshaft thrust washer (Figure 53).

14. Press the countershaft out of its access door bearing as
follows:

a. Remove the access door from the vise and install the

countershaft gear support plate (part No. HD-37404)
under countershaft fourth gear as shown in Figure 54.

b. Support the countershaft gear support plate on some

metal blocks in a press so the countershaft can be
pressed out without any interference. Center the
countershaft under the press ram. See Figure 55.

c. Place a mandrel on top of the countershaft and press

the countershaft out of the access cover. Catch the
countershaft assembly (Figure 56) so it does not fall
onto the floor.

15. Remove the following components from the count-
ershaft:

a. Bevel spacer (Figure 57).

b. Countershaft fourth gear (Figure 58).

c. Snap ring (A, Figure 59) and thrust washer (B) posi-

tioned next to first gear.

d. Countershaft first gear (C, Figure 59).

e. Split bearing (A, Figure 60).

f. Thrust washer (B, Figure 60).

g. Snap ring (C, Figure 60).

312

CHAPTER NINE

16. Remove the snap ring and mainshaft first gear (Figure
61).
17. Press the mainshaft out of its access door bearing as
follows:

a. Support mainshaft fourth gear in a press as shown in

Figure 62. Make sure the mainshaft can be pressed
out without any interference. Center the mainshaft
under the press ram.

b. Place a mandrel on top of the mainshaft and press the

mainshaft out of the access cover. Catch the
mainshaft so that it does not fall to the floor.

18. Remove the following components from the main-
shaft:

a. Spacer (19, Figure 40).
b. Mainshaft fourth gear (18, Figure 40).
c. Split bearing (16, Figure 40).
d. Thrust washer (14, Figure 40).
e. Snap ring (13, Figure 40).

Inspection

The manufacturer does not provide dimensional or ser-

vice specifications.

Replace parts that are excessively worn or damaged as

described in this section.
1. Clean all components in solvent and dry with com-
pressed air.

NOTE

Defective gears should be replaced. It is a
good idea to replace the mating gears as a set.

2. Check each gear tooth for excessive wear, burrs, galling
and pitting. Check each gear for missing teeth. Make sure
the gear lugs are in good condition.
3. Install each splined gear (Figure 63) on its respective
shaft and check for excessive play or binding.
4. Check each sliding gear (Figure 64) for scoring, galling
or seizure marks. Spin the gear on its shaft; it should turn
freely.
5. Check the groove in each sliding gear (Figure 63) for
severe wear or damage. If the groove is worn or damaged,
check the mating shift fork for damage. Replace the gear if
necessary.
6. Check the bearing surface on each shaft. These surfaces
must be smooth. See Figure 65 and Figure 66.
7. Check the shaft splines (Figure 67) for severe wear or
damage.
8. Inspect the snap ring grooves (Figure 68) in each shaft.
Each groove must have sharp square shoulders. If any are
worn or damaged, the shaft(s) must be replaced. See the
damaged splines in Figure 69.
9. Check the split bearings (Figure 70) for severe wear or
damage.
10. Check the thrust washers for galling, scoring, cracks or
other damage. If the washers are not smooth, replace them.
11. Check the countershaft (Figure 65) and mainshaft
(Figure 66) for bending, damaged splines or other abnor-
mal wear.

Assembly

Refer to Figure 40.

CAUTION

Replace all snap rings to ensure proper gear
alignment and engagement. Do not expand a
snap ring more than necessary to slide it over
the shaft.

1. Apply a light coat of new transmission oil to all sliding
gear and shaft sliding surfaces and split bearings (Figure
70) prior to installing any part.
2. If removed, install the access door bearings as described
in this chapter.
3. Press the mainshaft into its bearing as follows:

CAUTION

The bearing driver must press against the in-
ner bearing race or bearing damage results.

a. Place a bearing driver (A, Figure 71)in a press that

matches the mainshaft bearing inner race diameter.
Place the bearing inner race on the driver so that the
access door inner surface faces up as shown in B,
Figure 71.

FIVE-SPEED TRANSMISSION (1991-2003 MODELS)

313

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 31