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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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Old 27th September 2010
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Default '77 transmission thrust washer thicknesses

I putting my transmission back together and into the bike and I would like to know what the thicknesses of the Main Shaft Thrust Washer, the Main Shaft Third Gear Washer, and the Main Shaft Roller Bearing Washer are. I have various washers that came with the bike, some new some old. I put the bike together without the Main Shaft Thrust Washer by mistake and had too much main shaft end play, .018" instead of the .003"-.009" spec'd in the book. When I took it back apart I realized my mistake, but the only washer I have that fits that spot is .040, I did try this but find that my main shaft and clutch shaft bind and can no longer spin freely if I try and tighten down the cover, I see there are 2 Main Shaft Thrust Washers, the one with the tab that goes alongside the main shaft 1st/low gear is easy to identify so I think that one is ok, its the one that fits up against 4th gear that the main shaft bottoms out against that I measured at .040"....
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Old 27th September 2010
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they come if different sizes so you can get the proper spacing between gears and endplay. one of the thrust washers will go on the outside of the trans behind the sprocket and between the circlip and bearings. if ya forget that one it will mess up the mainshaft, bearings and race at least.
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