811
4-Speed
Transmission
Complete XLH-XLCH 4 Speed Transmission Gear
Assembly Unit includes gears, main and counter shaft,
shift forks & shafts assembled to trap door. Order right
side case races, rollers, shims, & bearings separately.
Shift selector shaft included.
VT No. Years
17-0028 1956-66 XLH-XLCH, 1967-69 XLCH
Note: Main & countershaft end play and trap door align-
ment w/case must be established and adjusted before
final assembly.
1984-90 Units
include Billet door
by Sifton
All XL Transmission assemblies are bench tested for positive gear engagement and dis-
engagement but it is always best for a final check after unpacking transmission before
being installed.
All V-Twin Transmissions are assembled with late style shifter cam plate that uses welded
in pin for neutral switch indicator. On some early (Pre 1974) case this pin may have to be
shortened or removed to allow cam plate to move freely. Failure to check this will cause
transmission to not completely shift through all gears. This should be checked first prior to
assembly.
Gear Engagement Check
Rotate pawl carrier (EE) until pawl carrier contacts lifter arm (Y+X). Hold the shifter cam
(D) with opposite hand to prevent cam follower (I) from completing gearshifts. If hand
pressure is released from shifter cam the gears will be drawn into complete engagement
and all inspection procedures will be performed incorrectly.
Shift transmission into first gear then check gear to dog Pocket Engagement. Correct
engagement should be 25%.
Shift transmission into all other gears checking Pocket Engagement, which must be at
least 50%.
Filing of lifter arms (Y+X) will produce changes in Pocket Engagement.
Installation
Establishing Mainshaft and Countershaft Endplay
Use the thinnest low gear washer and mainshaft washer. On 1954-early 84 models the
mainshaft thrustwasher must be installed with Tang Down. For 1954-early 1984 models
the mainshaft needle bearing will have to be installed. Temporarily install access cover to
crankcase with all transmission parts. Carefully align Cover Dowel Pins and with a
rawhide mallet tap into position and install four cap screws.
When installing transmission into case check shift fork shaft for correct alignment to case.
Do not force transmission into case if shift fork shaft will not go in to case. If shift fork
shaft is forced into case damage or bending to shaft will happen causing shifter roller fin-
ger to bind against shifter cam plate or shifter fork binging on shaft or with pawl carrier
assembly.
On 1954-E84 Models Inspect case race and rollers, if badly pitted scorred or worn they
should be replaced. Correct fit of main bearing is .0006in-.0014in. If clearance is beyond
specified limit a new race and bearings must be installed, and line lapped for proper fit.
Note: Fitment of door to case may sometimes requires reaming of holes in access door
or removal of alignment pins from case. If removal of dowel pins is necessary tapping
dowel pin holes and use of additional bolts is suggested.
Note also that even during factory assembly process several access doors were tried
before final assembly.
Using a Dial Indicator measure mainshaft endplay from sprocket side of shaft, press
against clutch gear so that bearing seats against lock ring in access cover. Move shaft
back and forth and measure endplay while holding clutch gear in. If endplay is not with
specification (see char t) install thrust washer of suitable size.
With access cover still in place bend a discarded spoke or other suitable wire and wedge
into hole on end of countershaft. Push and pull countershaft and measure endplay with
dial indicator. If endplay is not within specification (see chart) install countershaft washer
of suitable size.
After countershaft endplay has been established install oiler plug in access cover with oil
hole up.
Note: On 1959-early 84 models the clutch must be temporarily installed and the 1984-85
models the Stator spacing ring and the Stator must be installed on access door before
above End Play clearances can be established.
When Mainshaft and Countershaft end play established install new shifter shaft into the
crankcase so that the shifter lever arm is centered. Using a grease pencil mark the shaft
at the 12 o’clock position by marking the shaft you can tell if the shifter lever arm position
changes when installing the transmission. Correct shaft to shifter pawl yoke engagement
is important for proper gear shifting. Install transmission and rotate countershaft slowly to
check that ghe gear shift arm is engaged with shifter pawl. To do so rotate shift lever, a
noticeable resistance to movement indicates proper engagement.
Transmission End Play Specifications
1956-78
1979-E84 L1984-85
Countershaft
0.004-0.009
0.007-0.015 0.004-0.015
Mainshaft
0.003-0.009
0.003
0.003
