Transmission Removal and Reinstallation: 86-90 Evo Sportster Motorcycle

I wasn't expecting to dig into my transmission in the middle of my Sportster refurbishment series, but unfortunately, I dropped my bike and broke the shifter. So here we go. In this episode, I will walk you through how to remove and reinstall a 1990 Sportster transmission so I can replace my shifter.
#1986 #1987 #1988 #1989 #1990 #harley #harleydavidson #Evo #sportster #sportster883 #motorcycle #transmission #transmissionrepair #howto #diy #motorcyclemechanic #mmi #motorcyclemechanicsinstitute

[@hni7458]

Ain't the first time this guy is fixing a bike - seems so easy when you watch someone who is really good. Mine's an '86, 1100cc, so much appreciated. This is all I'll ever need to explain the prime side of this bike - sooo good footage and talk as well; 10/10.

[@makerhackshack5608]

Thank you for the kind words.

[@walterm5911]

Thanks for this video. There’s so little content on the 1986-90 sportsters on KZbin.

[@maryspeight2840]

Outstanding . I still have my 89 sporty chop i built 20yrs ago. Cousre ii's got a 94 1200 bone stock brother, a 95 sporty i got just to flip and way over in the corner sits my 70 flh that really needs some love . Good stuff man , ride / wrench safe . Guy Speight

[@Yo-mamashouse]

Lol I just did this on my 86 last sat!!! mine didn't have the washer on the tension shoe spring......

[@jknick04]

Thank you, I picked up a 86 sportster 883 with the 1200 kit. Been looking for a video to help as I dive into the transmission.

[@mikeyp03]

Hey great video, just picked up a 89 Sportster 883 w/ S&S 1200 kit. Need to take a dive into trans due to shifter being unseated and bike stuck in second. Any place I can find a detailed manual with instruction on how to o this online? Thanks

[@makerhackshack5608]

First, you can open it up to see if you find anything burnt, bent, or broken. I recommend looking for a Harley service manual for your model. You'll need a jig to check all your clearances. It's pretty complex. You might want to find someone who knows those transmissions.

[@dakotamantai1517]

Hey I have the same motor, do you have a picture of the the gearbox assembly I can follow to rebuildm

[@michaelmerritt9657]

I got it apart. It seems that there’s some kind of shim that was broken up at the end of the shaft. That was broken. Did that piece come with your new shifter shaft ?

[@makerhackshack5608]

No, that's just an end plate. You can likely buy the shim separately.

[@michaelmerritt9657]

@@makerhackshack5608 I appreciate the reply. I found my issue. Is there some way I could send you a picture? My bike was popping out of second gear. I pulled the trans, but I don’t know the name of the particular part that broke. Please let me know. Seems like you have more insight than me for sure

[@makerhackshack5608]

I suspect you are having issues with the detent assembly. Look that up to see if it looks like what is giving you issues. You can send an email to me at [e-mail]

[@paulmorford4569]

I'm in the middle of changing my stator on my 86. My shifter has quite of bit what I call end play back and forth. Normal? How to fix? Which part do I fix?

[@makerhackshack5608]

There are shims that go behind the shifter to set proper end play tolerance.

[@Rickvales]

Thank you for making this video I’ve been looking for a how to like this

[@josephskubis9269]

What rim and tire you running on the rear?

[@makerhackshack5608]

It's a 21" front wheel and tire I laced to the stock hub.

[@laurencooper4771]

My stator is super stuck, what can I do?

[@makerhackshack5608]

It should just come off when you remove the 4 bolts.