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  #1  
Old 10th November 2011
73novaguy 73novaguy is offline
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Sportster/Buell Model: Sportster 883
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Default Zippers install, shaft endplay

Just put my old gearset onto the new Zippers billet trap door. In the Zippers directions it recomends .008-.014 countershaft endplay. mine was .029. When removing the OEM gearset and installing to the Zippers trap door then puting back into trans case, how did it get so out of spec? Also what have you guys been using for thrust washer to space the mainshaft and countershaft endplay? The way the book read they want you to measure mainshaft endplay on the clutch side of the mainshaft, mine doesnt even budge on the clutch side but was a very snug fit getting the mainshaft into the Zippers trap door double row bearing. I get a very slight amount of end play on the mainshaft on the drive sprocket side and absolutely zero endplay on the clutch side of the mainshaft. But my countershaft (read from the clutch side of bike) reads right around .029 How close tolerances do you keep it at, where have you been getting thrust washers, and why am I not getting any endplay out of the mainshaft?

I wanna get this buttoned up cause I installed the new Barnett extra plate kit in the clutch hub tonight and want to get things back together. I ordered the stiffer Barnett clutch spring but have been hesitant to install it with fear it wil be snapping clutch cables.

Thanks guys
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  #2  
Old 11th November 2011
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  #3  
Old 11th November 2011
73novaguy 73novaguy is offline
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Thanks for the bump, I went through last night and took out all of the shims on the countershaft and mainshaft and reinstalled trans, the countershaft has . 092 endplay which the manual calls for .085 worth of thrust shims, if I put .085 worth of thrust shims in my end play is way more than spec still because it had .155 worth of shims in it when I took it apart and it had around .029 worth of end play then, so I'm not totally hip on whats going on in there. I pulled OEM trap door (NRHS already installed the bearing in the Zippers door) and removed the two shafts and shifter mechanisms and installed them directly to the Zippers door, so nothing was dissassembled other than unbolting the shift fork assembly and moving the two gear shafts from one door to the other, then reinstalling shift mechanism.

The mainshaft has absolutely zero end play if you check it on the clutch side, I dont see how it can have endplay when its a tight fit (not slip fit, but not press fit)through the trap door bearing. But if I check the endplay on the drive sprocket side of the mainshaft I have .1 endplay, which the manual calls for a .087 to .082 thrust washer, but I dunno if checking there is correct since the manual says to check on the clutch side. Looking for any help, my first time pulling a trans on a XL.

Thanks, Bishop
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Old 11th November 2011
73novaguy 73novaguy is offline
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Maybe Im not even looking at the right thrust washers, but from what I can tell they are the ones you would want to replace to correct endplay. They are the ones that are on the end of the main and counter shafts (that come in contact with the transmission inner case or no? Just googled a few of the part #'s for the thrust washer and the exploded view JP cycles gives, shows them to be between the gears.
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Old 17th November 2011
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Got it all buttoned up, ended up getting the answer over at Club Chopper. Here like a goof ball I was trying to measure end play on the clutch side like I should, but was measuring off the splined clutch hub, the part the you should be measuring off from is inside the splined clutch hub. Regardless, end play should be the same from either side of the mainshaft (drive sprocket side or clutch side) and it was. Got both main and counter shaft spec'd out to the bottom end of the free play specs, installed the stator, V-Twin sealed magnet, Barnett extra clutch plate kit and all buttoned up last night, except waiting on a custom clutch cable from Motion Pro to show up. I had to re-order one cause I forgot to specify where I wanted the adjuster located at on the cable and they put it on the end of the cable by the primary, I wanted mine by the downtubes, that should be here today. Thanks again for looking.
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Old 17th November 2011
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Old 24th August 2016
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I got a basketcase and am not sure which countershaft Variable thrust washers I need to use on my late 84 Transmission. In the photos below, there are 3 washers and 1 is #19 and the other is #11 in the FSM. One of the two smaller washers that controls clearance between gears should go before 1st gear? The bigger washer sits inside 1st gear and controls countershaft end play? Or does one of the smaller washers control end play? The two smaller washers are different thicknesses. One is 0.065" and the other is 0.047". The larger washer is 0.067". Any help on which ones go where on the countershaft a is appreciated.

-Luke



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  #8  
Old 25th August 2016
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Default Zippers install, shaft endplay

My plan is to measure gear spacing between 3rd and 1st & then use the appropriate thrust washer. Then use the other two for end play and see how it ends up. Thanks

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  #9  
Old 21st January 2017
Dookie1032 Dookie1032 is offline
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Well I have put this off long enough. I replaced a few gears with Andrews and I think I've got this countershaft laid out correctly. Please let me know if anything looks out of place for this Late 1984 XL1000. Thanks




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  #10  
Old 22nd August 2021
salmanmr salmanmr is offline
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Any update?
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