Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 23

286

CHAPTER EIGHT

TRANSMISSION

1. Needle bearing
2. Inner race
3. Thrust washer
4. First mainshaft gear
5. Mainshaft
6. Third mainshaft gear
7. Washer
8. Circlip
9. Second mainshaft gear

10. Circlip
11. Thrust washer
12. Bearing
13. Clutch gear
14. Needle bearing
15. Bearing

16. Circlip
17. Access cover
18. Countershaft bearing closed end
19. Washer
20. First countershaft gear
21. Bearing
22. Washer
23. Third countershaft gear
24. Countershaft
25. Thrust washer
26. Second countershaft gear
27. Spacer
28. Fourth countershaft gear
29. Countershaft bearing open end

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

287

Mainshaft

8. Remove the shift fork (Figure 17). Then remove the fin-
ger rollers (Figure 14) from the shift fork.
9. Pull the countershaft (Figure 18) from the access cover.
10. Remove the following from the countershaft:

a. Fourth gear (Figure 19).
b. Spacer (Figure 20).
c. Second gear (Figure 21).
d. Thrust washer (Figure 22).

11. Remove the following from the mainshaft:

a. Circlip (8, Figure 7).
b. Washer (7, Figure 7).
c. Third gear (6, Figure 7).
d. Thrust washer (3, Figure 7).

NOTE

To remove the mainshaft first gear (4,

Figure

), the bearing inner race (2) must be pressed

off the shaft. Complete disassembly is only re-
quired for part replacement.

12. Support the first gear in a press. Then press against the
mainshaft and remove the bearing inner race and first gear.
First gear will be loose once the bearing inner race is free of
the mainshaft.
13. Refer to Figure 23. Remove the clutch gear from the
access cover as follows:

a. Remove the snap ring (Figure 24).

288

CHAPTER EIGHT

b. Tap the clutch gear shaft and bearing (Figure 25) out

of the access cover. See Figure 26.

Transmission Inspection

1. Examine gears (A, Figure 27) for worn or chipped
teeth, pitting, scoring or other damage. If the gears appear
okay, make the following checks:

a. Install the splined gears on their respective shafts and

check for binding or excessive play (Table 1).

b. Install stationary gears on their respective shafts and

place them at their point of operation. Spin these
gears and check for binding or rocking. Rocking is
caused by excessive inside diameter bushing wear
(B, Figure 27).

c. Replace gears as necessary.

NOTE

Early 1986 883 models use different trans-
mission gears than later 1986 883 models. All
1100 models use the later type transmission
gear sets. Only later type gears can be used
in 1100 transmissions. The only way to deter-
mine which gear set is installed in a 1986 883
model is to measure the gears outside diame-
ter as shown in

Figure 28

and compare the

measurements to

Table 2

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

289

Snap ring

Clutch gear and
bearing assembly

Access cover

Slots face away
from bearing

Flat side
toward bearing

NOTE

When replacing a worn gear(s) it is advisable
to also replace the mating gear(s) to prevent
accelerated wear to the new gear(s).

NOTE

When replacing gears, note that all 1987
models are equipped with close ratio gears.
To install close ratio gears in a 1986 model,
refer to

Close Ratio Gear Installation

in this

section.

2. Examine the dog clutches (Figure 29) for chips and
rounded edges or wear.

3. Check the shafts (Figure 30) for worn splines and worn
or damaged circlip grooves.

CAUTION

The needle bearings installed in the transmis-
sion gears, access cover and crankcase hous-
ing are press-fit. Replacement of these
bearings requires a press or special bearing
replacement tools. Driving in the bearings
will damage them. If the proper tools are not
available, refer replacement to a dealership.

4. Inspect the needle bearings for wear, needle damage or
roughness. Replace the bearings if necessary.

5. Replace worn or damaged thrust washers.

CAUTION

Excessive transmission shaft runout will
cause vibration and excessive gear wear.

6. Mount the mainshaft or countershaft in a suitable center-
ing device. Rotate each shaft and measure bend with a dial
indicator. Replace either shaft if it is bent more than 0.003
in. (0.08 mm).

7. Check the shift fork shaft for cracks, deep scoring or
wear. Check the shaft for bending by rolling it on a piece of
glass or other flat surface. If the forks do not roll smoothly,
the shaft is bent.

290

CHAPTER EIGHT

8. Check the shift forks (Figure 31) for cracks, deep scor-
ing or excessive wear.
9. Shift fork length varies. If replacing a shift fork, be sure
to replace it with one of the same length (Figure 32).

Close Ratio Gear Installation

An internal gear ratio change was made starting on 1987

models. All 1987-1990 models are installed with close ratio
gears. Refer to Table 3 for a complete listing of gear ratios.
Owners of 1986 models who wish to install close ratio
gears should note the following:
1. The close ratio gear set is composed of three new gears:
mainshift first gear, countershaft fourth gear and the clutch
gear. See Figure 33.
2. Close ratio gears are identified with grooves machined
into the face of the gears. Figure 34 identifies the new gears
and their markings. Note that the clutch gear will have its
groove cut into the dog faces.
3. Refer to Figure 33 and note the following installation
conditions:

a. The new mainshaft first gear can be used with any

17-tooth countershaft first gear.

b. A new clutch gear and countershaft fourth gear must

be installed as a pair.

c. Service and installation procedures remain the same

as for 1986 models.

Access Cover Inspection/Bearing Replacement

CAUTION

1. Check the clutch gear ball bearing (Figure 35).
2. Check the needle bearing (Figure 36) for wear or rough-
ness.

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

291

Clutch gear

Mainshaft

Countershaft

First
Third

Second

Fourth

Identification groove

Clutch gear

Countershaft
fourth gear

Identification groove

Mainshaft
first gear

NOTE

Remove the circlip (16,

Figure 37

) before re-

placing the bearing (15).

3. Check the clutch gear ball bearing surface in the access
cover for wear or damage. Replace the access cover if nec-
essary.

Transmission Assembly

Refer to Figure 37.

CAUTION

Always install new circlips when reassem-
bling the transmission and gear shifter as-
semblies.

1. Install the shift mechanism onto the access cover as de-
scribed in this chapter.

2. Install the mainshaft thrust washer so that the grooves
on the washer face toward the transmission.

3. Slide the clutch gear and bearing assembly through the
access cover until the bearing bottoms on the cover shoulder.

292

CHAPTER EIGHT

TRANSMISSION

1. Needle bearing
2. Inner race
3. Thrust washer
4. First mainshaft gear
5. Mainshaft
6. Third mainshaft gear
7. Washer
8. Washer
9. Second mainshaft gear

10. Circlip

11. Thrust washer
12. Bearing
13. Clutch gear
14. Needle bearing
15. Bearing
16. Circlip
17. Access cover
18. Countershaft bearing closed end
19. Washer
20. First countershaft gear

21. Bearing
22. Washer
23. Third countershaft gear
24. Countershaft
25. Thrust washer
26. Second countershaft gear
27. Spacer
28. Fourth countershaft gear
29. Countershaft bearing open end

4. Install a new snap ring (Figure 23) so that the flat side
faces the bearing.

5. Assemble the following components on the countershaft
in the following order:

a. Second gear thrust washer (Figure 22).

b. Second gear (Figure 21).

c. Spacer (Figure 20).

6. Install the countershaft 4th gear so that the recess por-
tion (Figure 38) faces toward the spacer. See Figure 39.

7. Make sure the countershaft second gear turns freely on
countershaft.

8. Install the countershaft assembly (Figure 40) into the
access cover so that the countershaft fourth gear engages
with the mainshaft clutch gear.

9. Install a finger roller (Figure 41) on each shift fork stud.

10. Install the mainshaft second gear with its shift fork
(Figure 42). Position the shift fork so that the finger roller
stud faces toward the transmission access cover. Make sure
the shift fork finger engages the gear slot.

11. Install the countershaft third gear (A, Figure 43) and
corresponding shift fork (B). Engage the shift fork finger
roller into the gear slot (Figure 44).

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

293

12. Install the shift fork shaft (Figure 45) so it passes
through both shift forks and bottoms into the access cover.
Make sure the shift forks engage the shifter cam after in-
stalling the shift fork shaft.
13. Install the variable washer (Figure 46) onto the
countershaft.
14. Install the countershaft first gear (Figure 47) and the
washer (Figure 48).

NOTE

If the inner race and first gear were not
pressed off the mainshaft, proceed to Step 16.

15. Refer to Figure 37. If the inner race (2, Figure 37) and
first gear (4) were pressed off of the mainshaft, perform the
following:

a. Slide first gear (4, Figure 37) on the mainshaft so that

its oil retention groove faces toward the bearing inner
race (2).

b. Align the inner race over the mainshaft so that the let-

ter side faces up. Press against this side only.

c. Press the inner race (2, Figure 37) onto the mainshaft

until it touches first gear.

d. When the inner race is properly installed, the

mainshaft first gear will have no end play. Check by
attempting to twist the gear upward.

e. Install the mainshaft thrust washer (3, Figure 37)

over the inner race and against first gear.

16. Slide third gear (6, Figure 37) and its washer (7) onto
the mainshaft. Install a new circlip (8, Figure 37) in the
groove next to the washer (7).
17. Install the mainshaft assembly through second gear
and into the clutch gear assembly. See Figure 49.
18. Perform the

Transmission Gear Spacing Check

as de-

scribed in this section.

Transmission Gear Spacing Check

Measure transmission gear spacing using a feeler gauge

and the transmission gear spacing tool (part No. HD-35820
[Figure 50]). Figure 51 identifies the check points.
1. Slide the countershaft washer (19, Figure 37) and first
gear (20) off the countershaft.

294

CHAPTER EIGHT

2. Place the access cover in a vise or support it on wood
blocks so that the transmission shafts face up.

3. Align the transmission gear spacing tool holes with the
mainshaft, countershaft and shift fork shaft holes and install
the tool. Press down on the tool so that it is positioned as
shown in Figure 52.

4. Shift the transmission into neutral.

5. Measure the minimum clearance between the mainshaft
second gear and the clutch gear dogs using a 0.040 in. feeler
gauge. The feeler gauge should move freely between the
gears without moving them.

6. Insert a 0.080 in. feeler gauge between mainshaft third
gear and the dogs on mainshaft second gear (Figure 51).
The maximum limit is correct if the feeler gauge does not fit
or if there is a slight drag when the feeler gauge is inserted
and withdrawn.
7. Lift the mainshaft second gear shift fork and raise sec-
ond gear. Make sure that the shift fork is flush against sec-
ond gear. Then insert a 0.080 in. feeler gauge between
mainshaft second gear and the clutch gear dogs (Figure
51). The maximum limit is correct if the feeler gauge does
not fit or if there is a slight drag when the feeler gauge is in-
serted and withdrawn.
8. Repeat Step 7 and measure the clearance with a 0.040 in.
feeler gauge. If the 0.040 feeler gauge is too tight, the mini-
mum clearance is incorrect.
9. If any gear space checked in Steps 5-8 is incorrect, replace
the mainshaft second gear shift fork. Shift forks are available
in three sizes standard plus 0.020 in., standard, and standard
minus 0.020 in. Figure 53 identifies shift fork markings.
10. Shift the transmission into neutral.
11. Measure the minimum clearance between countershaft
second gear and the third gear dogs (Figure 51) with a
0.040 in. feeler gauge. The feeler gauge should move freely
between the gears without moving them.

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

295

Mainshaft

Clutch gear

Neutral position

First

Third

Second

Fourth

Countershaft

Gear spacing
0.040 to 0.080 in.
(4 places)

Mainshaft

HD-35820

Countershaft

Access
cover

C: Standard

+: Standard plus 0.020 in.
–: Standard minus 0.020 in.

12. Lift the countershaft third gear shift fork and raise third
gear. Make sure that the shift fork is flush against second
gear. Then insert a 0.080 in. feeler gauge between
countershaft third gear and countershaft second gear (Fig-
ure 51). The maximum limit is correct if the feeler gauge
does not fit or if there is a slight rag when the feeler gauge is
inserted and withdrawn.

13. If any gear space checked in Step 11 and Step 12 is in-
correct, replace the countershaft third gear shift fork. Shift
forks are available in three sizes: standard plus 0.020 in.,
standard, and standard minus 0.020 in. Figure 53 identifies
shift fork markings.

14. Remove the transmission gear spacing tool (Figure
52) and turn it over. Align the tool holes with the mainshaft
and shift fork shaft and install it (Figure 54).

15. Shift the transmission into neutral.

16. Measure from the top of countershaft third gear to the
countershaft spline shoulder (Figure 55).

17. Compare the measurement taken in Step 16 with the
measurements in Table 4. Then measure the countershaft
washer (19, Figure 37) originally installed in your trans-
mission and cross-reference it with the washer part num-
bers in Table 5. If the correct washer is used, the
countershaft gear spacing is correct. If the washer is differ-
ent, select the washer(s) from the list in Table 4 that corre-
sponds to the measurement taken in Step 16.

NOTE

If the variable thrust washer is changed,
check and reshim the countershaft end play as
required. See

Mainshaft and Countershaft

End Play Check and Adjustment

in this

section.

Mainshaft and Countershaft End Play
Check and Adjustment

1. Temporarily install the assembled transmission assem-
bly as described in the

Transmission Installation

in this

section. It is not necessary to install the shift shaft.

2. Install the access cover bolts (Figure 56) and tighten to
14-19 ft.-lb. (19-26 N•m).

3. Install a dial indicator so that its tip rests against the end
of the mainshaft on the clutch side of the engine. Move the
mainshaft back and forth by hand and measure end play.
Record the measurement.

4. Cross-reference the end play measurement taken in Step
3 with the list in Table 6 and install the correct mainshaft
thrust washer (3, Figure 37).

5. Install a dial indicator so that the tip rests against the end
of the countershaft on the clutch side of the engine. Then
bend a piece of strong wire or welding rod and wedge it into
the hole in end of countershaft (clutch side). Push and pull
countershaft and measure end play with a dial indicator. Re-
cord the measurement.

6. Cross-reference the end play measurement taken in Step
5 with the list in Table 7 and install the correct variable fit-
ness washer(s) (19, Figure 37).

7. Remove the transmission as described in this chapter
and install the correct thrust washer(s) if necessary.

SHIFTER MECHANISM

Disassembly/Assembly

Refer to Figure 57.

296

CHAPTER EIGHT

Mainshaft

Shift fork shaft hole

Countershaft

Countershaft shoulder

Top of countershaft

Third gear

“A”

Access cover

Bolt

Three bolts

FOUR SPEED TRANSMISSION (1986-1990 MODELS)

297

SHIFTER MECHANISM

1. Lever
2. Shift lever
3. Oil seal
4. Bushing
5. Thrust washer
6. Washer
7. Screw
8. Shift lever
9. Bushing

10. Spring
11. Cam follower
12. Finger rollers
13. Shift forks
14. Shift fork shaft
15. Pins
16. Lockplate
17. Cam support pin
18. Cam capscrew

19. Pawl carrier springs
20. Carrier spring retainer plugs
21. Upper pawl lifter arm
22. Circlip
23. Thrust washer
24. Pawl carrier support
25. Lower pawl lifter arm
26. Pawl spacer
27. Pawl
28. E-clip
29. Pawl carrier
30. Pawl
31. Spacer
32. Retaining ring
33. Neutral switch pin
34. Shifter cam
35. Pawl springs
36. Access cover

NOTE

Take careful note of location and orientation
of each component as it is removed.

1. Remove the transmission and shift forks from the access
cover as described in this chapter.

NOTE

It is not necessary to remove the clutch gear
from the access cover when removing the shift
mechanism.

2. Remove the cam capscrew (18, Figure 57) and
lockplate (16) from the front of the access cover. Then
remove the cam follower (11, Figure 57) and springs
(10).

3. Lift the pawl carrier support (24, Figure 57) away from
the access cover.

4. Remove the circlip (Figure 58) and thrust washer (Fig-
ure 59) from the outside of the pawl carrier support.

5. Lift the pawl carrier support (A, Figure 60) off of the
shifter cam (B, Figure 60).

6. Remove the pawl carrier springs (Figure 61).

7. Remove the retainer plugs from the end of the pawl car-
rier springs (20, Figure 57).

8. Disassemble the pawl carrier as follows:

a. Lift the pawl carrier (Figure 62) off of the shifter

cam.

b. Remove the E-clip (Figure 63) and remove the pawl

spacer (Figure 64).

298

CHAPTER EIGHT

4. Disconnect and remove the cable straps securing the
voltage regulator wiring harness to the frame. Pull the wir-
ing harness away from the frame.
5. Remove the voltage regulator mounting fasteners and
remove the voltage regulator.
6. Install by reversing the removal steps.

IGNITION SYSTEM

(1986-1997 MODELS)

The ignition system consists of a single ignition coil, two

spark plugs, inductive pickup unit, ignition module and a
vacuum operated electric switch (VOES). This system has

a full electronic advance. The inductive pickup unit is
driven by the engine and generates pulses which are routed
to the solid-state ignition control module. This control
module computes the ignition timing advance and ignition
coil dwell time eliminating the need for mechanical
advance and routine ignition service.

The VOES senses intake manifold vacuum through a car-

buretor body opening. The switch is open when the engine
is in low vacuum situations such as acceleration and high
load. The switch is closed when engine vacuum is high
such as during a low engine load condition. The VOES al-
lows the ignition system to follow two spark advance
curves. A maximum spark curve can be used during a

408

CHAPTER TWELVE

IGNITION SYSTEM

(1986-1993 MODELS)

1. Gearcase cover
2. Oil seal
3. Rotor
4. Bolt
5. Sensor plate
6. Sensor plate screw
7. Gasket
8. Inner timer cover

9. Screw

10. Outer cover
11. Rivet
12. Ignition module
13. Connector
14. VOES
15. Vacuum hose

high-vacuum condition to provide improved fuel economy
and performance. During low vacuum conditions, the spark
can be retarded to minimize ignition knock and still
maintain performance.

The timing sensor is triggered by the leading and trailing

edges of the two rotor slots. As rpm increases, the control
module steps the timing in three stages of advance.

Sensor Plate
Removal/Installation

Refer to Figure 41 or Figure 42.

1. Disconnect the negative battery cable as described in
this chapter.

NOTE

On 1991-1997 models, the sensor plate wiring
harness connector must be removed from the
end of the wiring harness prior to removing
the wiring harness through the gearcase cover.

2. On 1991-1997 models, disconnect the sensor plate wir-
ing harness connector. Then remove the connector from the
wiring harness as follows:

a. Note the position of each sensor plate wiring termi-

nal in the end of the connector.

ELECTRICAL SYSTEM

409

IGNITION SYSTEM

(1994-1997 MODELS)

1. Gearcase cover
2. Oil seal
3. Rotor
4. Bolt
5. Adjusting notch
6. Sensor plate
7. Sensor plate screw
8. Gasket (1994-1996 models)
9. Inner timer cover

10. Screw
11. Outer cover
12. Rivet
13. Vacuum-hose
14. VOES
15. Ignition module
16. Locknut
17. Washer
18. Bolt

b. On 1991-1993 models, remove the terminals from

the end of the connector using the Cannon Connector
Tool No. 201051.

c. On 1994-1997 models, remove the terminals from

the end of the connector as described in

Electrical

Connector

in this chapter.

3. Drill out the outer cover rivets (Figure 43) with a 3/8 in.
drill bit.
4. Using a punch, tap the rivets through the outer cover
(Figure 44) and remove the outer cover.
5. Using a punch, tap the rivets through the inner cover.
6. Remove the inner cover screws (Figure 45) and remove
the cover and gasket (Figure 46).
7. To help approximate ignition timing when installing the
sensor plate, mark an alignment mark of the sensor plate
mounting screws position on the sensor plate.
8. Remove the screws (Figure 47) securing the sensor
plate to the crankcase and pull the sensor plate out of the
gearcase cover.
9. Withdraw the sensor plate wiring harness through the
crankcase hole and remove the sensor plate.
10. Remove the rotor bolt (A, Figure 48) and rotor (B).
11. Installation is the reverse of the preceding steps while
noting the following.
12. To install the rotor:

a. Align the tab on the back of the rotor (Figure 49)

with the notch in the end of the crankshaft (A, Figure
50).

b. Apply threadlock (Loctite 242 or equivalent) to the

rotor bolt (A, Figure 48) and tighten it to 43-53
in.-lb. (5-6 N•m).

CAUTION

Route the sensor plate wires approximately 1
1/2 in. (38 mm) forward of the gearcase rear
edge. Wires routed farther to the rear may al-
low the wiring harness to contact the second-
ary

drive

chain/belt

and

sprocket,

damaging the wiring harness.

13. Insert the sensor plate wires through the gearcase cover
and route the wiring harness along the original harness path
noted during removal.

410

CHAPTER TWELVE

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