Also for anyone rebuilding their Evo 4 speeds I got some part numbers, for replacment parts. There are only a few but these are the usual ones that'll need replacing. Also the shift cam on these things tends to be a bit rough on the edges, a lot of books I've read recommend polishing the shift points and cam follower area for smoother shifting. It definitly works as i did it to my fathers bike. A lot of people recommend and myself included the Zippers billet trap door with double row bearing, this thing takes all side to side play out of the clutch reducing the chances of the magnets scraping the stator and causing a costly replacment. It's an expensive piece but well worth the cost IMO.
Mainshaft Endplay: 0.006-0.020
Countershaft Endplay: 0.004-0.015
Gear Spacing between the shift dogs: 0.040-0.080
Shift Cam Follower: 34063-84B
Shift Cam Follower Springs: 29980-84
Finger Rollers: 34168-52
Shifter Pawls: 34476-72
Clutch Friction Plate H-D: 36788-84 (7)
Clutch Steel Plate H-D: 36787-84 (5)
T27 Stator Screws: 2712 (4)
Shifter Fork Standard: 34291-52C (Surdyke H-D still has all the shift forks available)
Shifter Fork .020 Shorter: 34293-72A
Shifter Fork .020 longer: 34292-72A
If anyone is interested in changing back to the wide ratio gear set to get the taller 2.52 first gear, these are the part numbers. Surdyke H-D still has them.
Clutch Gear: 37448-84A
Countershaft Drive Gear:35695-58
Unfortionatly H-D dosn't carry the Main and Countershaft spacers anymore. NOS parts will have those. I'd rather use H-D then cheap Tiawan made garbage.
Mainshaft Thrust Washer - 0.0965: 35380-84
Mainshaft Thrust Washer - 0.0905: 35381-84
Mainshaft Thrust Washer - 0.0845: 35382-84
Mainshaft Thrust Washer - 0.0795: 35383-84
Mainshaft Thrust Washer - 0.0725: 35384-84
Mainshaft Thrust Washer - 0.0675: 35385-84
Countershaft Spacer - 0.055: 35860-86
Countershaft Spacer - 0.050: 35861-86
Countershaft Spacer - 0.045: 35862-86
Countershaft Spacer - 0.040: 35863-86
Countershaft Spacer - 0.035: 35864-86
Countershaft Spacer - 0.030: 35865-86
Mainshaft H-D: 35036-84A
Countershaft H-D: 35613-84
Here are some Andrews Part numbers for gears and shafts:
STOCK 2ND GEARS.
Part #252020 2nd main (23T) (replaces 35296-56 & 56A)
Part #252040 2nd counter (20T) (replaces 35750-58 & 58A)
STOCK 3RD GEARS.
Part #253050 3rd main (20T) (replaces 35305-56 & 56A)
Part #253030 3rd counter (23T) (replaces 35709-54A & 54B)
Part #258190 mainshaft (alternator) (mid-84-’90)
(replaces 35036-84A) (Solid shaft; no through hole)
STOCK 1ST GEARS.
Part #251050 main 1st (27T) (replaces 35277-52A)
Part #251060 counter 1st (17T) (replaces 35760-73 late only, 1973-1985). To fit 1986 and later requires early countershaft #259010
WIDE RATIO 1ST GEAR SETS
Changes 1st from 2.52 ratio to 2.68 for more low end torque with 21T or 22T trans sprockets.
Part #251010 (late only, 1973-1985). To fit 1986 and later requires early countershaft #259010
Part #259010 countershaft (1956-mid-84)
(replaces H/D# 35613-58)
I scanned some pages from the manuel to help people without one. However you should have one by your side when doing the work. This is for reference: