Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
Sponsored by:
Sponsored by:

88 Evo 4 Speed Rebuild

  #1  
Old 10-12-2008 | 04:16 PM
spartanxl's Avatar
spartanxl
Thread Starter
|
2nd Gear
Joined: Aug 2007
Posts: 6
Likes: 0
From: Okemos, MI
Default 88 Evo 4 Speed Rebuild

Well, after shredding 3rd gear, the gearbox was torn down and found 3rd main broken in half, a tooth broken on main 2nd and misc. damage to surrounding gears and forks.

I would attach a photo, but I guess I need a few more posts. After reassembly using new Andrews gears and replacing brass forks with steel, polishing the shift cam and new most everything else including a Zippers trap door, bench tested fine with smooth gear changes. Shimmed for endplay at approx. .012 for the main shaft and .010 for the counter. Gear spacing well within the .040 to .080 min.max.

After installation, the test drive was not very positive! Could engage only neutral, 3rd and 4th gears. Clutch adjustment and free play is good, and no nasty sounds. All I can think of is that the counter shaft 3rd gear is not sliding properly to engage 1st and 2nd. Anybody got any been there done that advice? I'm getting ready to pull the gearbox and hopefully will find something simple. Any thoughts on what would prevent CS 3rd from sliding properly? The shaft looks fine and all worked well on the bench.

Thanks for any input or insight.
 
Attached Thumbnails 88 Evo 4 Speed Rebuild-imgp0445.jpg  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
Mike Petrill
Primary/Transmission/Driveline/Clutch
2
04-21-2018 04:22 AM
brandnew
2014-2023 Touring Models
8
07-26-2017 11:54 AM
fdh161
Primary/Transmission/Driveline/Clutch
2
09-24-2014 12:35 PM
Spankinhenken
EVO
19
05-22-2013 07:29 PM
roundy
Sportster Models
11
08-13-2012 06:22 AM


Thread Tools
Search this Thread
Quick Reply: 88 Evo 4 Speed Rebuild



All times are GMT -5. The time now is 06:23 PM.