91 sporty
Seasoned HDF Member
Joined: Aug 2007
Posts: 8,195
Likes: 3,085
From: NW AR
Dr.Linda has a '87. Fantastic bike. Very reliable. Few oil leak issues, but hey, goes with the territory. She has outrun many a Twinkie across I-90. I'm not sure when they went to 5 speed, but there's nothing wrong with a 4 speed. Stock carb was POS. I put fuel injection on it. If I were to do it over, I would seriously consider a Mikuni or other CV carb, which would be a lot easier.
I'll add that I have heard of people having issues with a weak shifter fork. "They Say" to replace it with a stronger one. We have not had a problem.
I'll add that I have heard of people having issues with a weak shifter fork. "They Say" to replace it with a stronger one. We have not had a problem.
Last edited by Dr.Hess; Jun 23, 2014 at 07:29 PM.
Seasoned HDF Member
Joined: Dec 2010
Posts: 7,736
Likes: 1,524
From: Coromandel Peninsula New Zealand
Plenty wrong with 4 speeds...or potentially there is. Went to 5 in 92.
The issues with 4 speeds is twofold.
The clutch is not bolted to the main shaft, it is splined but is loosely held on with a circlip. The lack of a really good mounting means that the splines wear out, mainly on the shaft and then the clutch rattles like a **** and causes other issues like vibes, snatching and primary chain wear...also the alternator is on the back of the clutch and so when the clutch gets slack the rotor magnets hit the stator and disintegrate.
Prevention is a matter of turning down the stator core where it protrudes from the windings so the magnets won't contact the stator. It is also good practice to epoxy between the magnets so they don't break up if their glue goes soft (it usually does) and the resin spaces the magnets apart so they can move but not impact each other.
Inspect the clutch shaft splines every 20k miles for peace of mind.
Its an easy fix if it all goes south but a bit pricey.
The issues with 4 speeds is twofold.
The clutch is not bolted to the main shaft, it is splined but is loosely held on with a circlip. The lack of a really good mounting means that the splines wear out, mainly on the shaft and then the clutch rattles like a **** and causes other issues like vibes, snatching and primary chain wear...also the alternator is on the back of the clutch and so when the clutch gets slack the rotor magnets hit the stator and disintegrate.
Prevention is a matter of turning down the stator core where it protrudes from the windings so the magnets won't contact the stator. It is also good practice to epoxy between the magnets so they don't break up if their glue goes soft (it usually does) and the resin spaces the magnets apart so they can move but not impact each other.
Inspect the clutch shaft splines every 20k miles for peace of mind.
Its an easy fix if it all goes south but a bit pricey.
Seasoned HDF Member
Joined: Dec 2010
Posts: 7,736
Likes: 1,524
From: Coromandel Peninsula New Zealand
91 was the year for 5 speed so this may not apply to the OP if he is not looking at a 4 speed.
As for you my good Doctor the fix is to replace the inner hub and clutch gear, plus the resin fix on the magnets. There is a another Sporty Forum on the web that has heaps of info on this.
Some claim you need the trock trap door with double bearings but that doesn't fix this issue.
As for you my good Doctor the fix is to replace the inner hub and clutch gear, plus the resin fix on the magnets. There is a another Sporty Forum on the web that has heaps of info on this.
Some claim you need the trock trap door with double bearings but that doesn't fix this issue.
Seasoned HDF Member
Joined: Dec 2010
Posts: 7,736
Likes: 1,524
From: Coromandel Peninsula New Zealand
If its a 5 speed then there is very little to worry about...apart from the previous owner.
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Seasoned HDF Member
Joined: Apr 2010
Posts: 9,499
Likes: 7,802
From: Long Island, New York
1991 is definitely an Evo and first year for the 5 Speed. If it is a 1200 it will also have a rear belt drive, 883 will have a chain.
Shifter forks can be an issue. I had a problem with third gear for over ten years until the fourth different HD mechanic figured it out. New fork and the tranny has been all good since.
Frame is very thin behind the top shock mount, under the fender struts. They are pinched in at the factory for some reason, they like to crack at the pinch location. I would pull off a strut cover and take a look.
Besides that, a good bike that will start every time. Evo Sportsters are good like that.
Shifter forks can be an issue. I had a problem with third gear for over ten years until the fourth different HD mechanic figured it out. New fork and the tranny has been all good since.
Frame is very thin behind the top shock mount, under the fender struts. They are pinched in at the factory for some reason, they like to crack at the pinch location. I would pull off a strut cover and take a look.
Besides that, a good bike that will start every time. Evo Sportsters are good like that.
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