Introduction
This guide will show you how to change the oil in the transmission of the Evolution motor of the Harley-Davidson Sportster.
The Evolution Sportsters have wet clutch and primary drives. It is recommended to change the oil at 1,000 miles, then every 10,000 miles after that.
The manufacturer recommends using 20w50 oil. Make sure that the oil you use is approved for wet clutches. Many automotive oils are not, so we recommend purchasing an oil that specifically states it's formulated for use in motorcycle transmissions. 75w90 gear oil is often substituted for 20w50 motor oil in this application.
What you need
-
-
For the best access to the transmission drain plug, optimal draining, and accurate re-filling, we recommend working with the bike secured in an upright position.
-
-
-
Using a 5/32 Hex or Allen screwdriver, unscrew the two screws from the primary chain inspection cover.
-
Your inspection cover may not be round, depending on the year. However, it will be in the same location and secured by similar screws.
-
Remove the primary chain inspection cover from the transmission housing.
How do I get these off if they're real tight? I've already broken a few Allan keys trying and almost striped one of them
Lightly tap the Allen wrench ( like driving a nail)with a rubber mallet due to aluminum corrosion. This helps free the Allen bolt
-
-
-
The transmission drain plug is located on the underside of the transmission on the left side of the bike, near the kickstand bumper.
-
Place a drain pan underneath the drain plug.
-
Using a wrench, unscrew the transmission drain plug and remove it.
-
Allow all the oil to drain out of the transmission. It should take about five minutes.
-
-
-
-
Using a T27 screwdriver bit, remove the four screws holding the clutch inspection cover in place.
I saw somewhere it said to remove and replace these screws in sync, in a certain order? Why? And does it matter? I only have 4 screws on my '01 sportster. And how do you get the large O ring to stay in place when putting cap back on?
And how do you get the large O ring to stay in place when putting cap back on?
Lori, I have the same question. Did you figure it out? My first attempt it slipped down and then the cover leaked when I tried to start it up. The ring is slightly stretched so I’m going to purchase a new one and see if it will stay in place any better. I will report back if it is any easier for the new one to stay in place.
Update: The new o’ring was much easier to install and get it to stay in place. $2 from Harley shop.
How can I get the bolts out of the cover if they are stripped?
-
-
Tool used on this step:Heavy-Duty Spudger$4.99
-
Insert a heavy duty spudger or similar prying tool into the gap between the clutch inspection cover and the transmission housing near where clutch cable enters the housing.
-
Gently pry the clutch inspection cover away from the transmission housing.
What should I look for while it's open?
Not to mention that's where you check ur oil level for the trans but also ur clutch adjustment is be hind that cover. ( type in clutch adjustment for more info)
-
-
-
Re-insert the transmission drain plug into the transmission housing and hand tighten.
-
Using a 3/4" wrench, tighten down the transmission drain plug.
Why not just fill through the top of the oil tank????
That's not the same. The oil bag is the crankcase oil and this is showing
The trans oil. The oil is the same(20w50) but it's two different compartments.
The oil is not necessarily the same depending on the bike, make sure you check your manual.
I have a 2011 Iron 883 and the transmission requires GL-5 certified GEAR OIL (75w90).
Derek -
This is correct. Manuals will specify gear oil for transmission but conveniently you can use 20W-50 Synthetic V-Twin Motorcycle Oil for both engine and transmission lubricant. Amsoil Synthetic 20W-50 Synthetic V-Twin Motorcycle Oil is certified for motorcycle engines, transmissions, and chaincases. Whatever brand you go with it MUST specify motorcycle oil. Many folks are getting confused so I am including this message with each comment that is asking what kind of oil to use.
https://www.amsoil.com/p/20w-50-syntheti...Sir_Nerd -
Make sure rubber o ring is in good condition, mine was smashed out and my oil leaked out. Bike ok. Thanks this site was very helpful. Like the steps and the information.
-
-
-
Insert the nozzle of a funnel into the primary chain inspection hole.
-
Pouring slowly, pour approximately 1 qt of oil into the transmission.
-
As you pour, watch the clutch inspection hole. Make sure that the oil level stays below the edge of the clutch inspection hole.
You can use Amsoil 20w50 Synthetic V-Twin Motorcycle Oil. It is certified for engine, transmission, and primary chaincase lubricant. Manuals will specify gear oil as well (75w90), which is also appropriate to use. Note as Eric Essen wrote that these oils are defined differently. Link to the Amsoil 20w50: https://www.amsoil.com/p/20w-50-syntheti...
Sir_Nerd -
You need to use a motorcycle gear oil.. DO NOT put regular motorcycle motor oil in the transmission. Which is what I almost did after reading this because up top it says 20/50 motor oil. I went to motorcycle shop and asked what kind of transmission oil to use. He said that some people say u r supposed to b able to use the motor oil, but NOT to, as it is bad for the bike. Use gear oil meant for motorcycle transmissions
They say not to use 20w-50 for transmission.
They recommend 75w-90. Gear oil.
Make sure its says GEAR OIL.
Thats what I run on mine.
SAE 20w50 Motorcycle oil is what is recommended by Harley Davidson. Engine and gear oil are measured on different scales. SAE 20w50 is the same as 75w90 gear oil. Some modern synthetic automotive oils are not compatible with wet clutches. 20w50 is still the correct oil recommended by the manufacturer, just make sure not to buy an oil not approved for use with motorcycle clutches. http://www.harley-davidson.com/store/syn...
Amsoil 20w 50 is specifically for Harley motor oil and wet clutch, it is also the best.
Thanks very useful info for beginners
I poured a quart of primary oil and I still cannot feel the oil when I put my finger in there does it need another one
-
-
-
Using a 5/32" Hex or Allen screw head, re-install the primary chain inspection cover.
The inspection hole is used to set the timing.
What if the shift linkage don't come back like it should
I highly recommend the Lowbrow video on how to adjust the primary chain tension at 6 mins 49 seconds into the video:
https://www.youtube.com/watch?v=bwriCGZB... -
-
-
Using a T27 Screwdriver head, reinstall the clutch inspection cover. Install the screws in the following order:
-
Top
-
Bottom
-
Left
-
Right
-
Cancel: I did not complete this guide.
82 other people completed this guide.
33 Comments
but you CANT use gear oil for cluthc!!!
car motor oil CANT be used for bike cluthc!!! Motorcycle motoroil CAN!
Is synthetic 20w50 ok to use?
Jordan -
What the !&&* is a cluthc?
redin575 -
You can use Amsoil 20w50 Synthetic V-Twin Motorcycle Oil. It is certified for engine, transmission, and primary chaincase lubricant. Manuals will specify gear oil as well (75w90), which is also appropriate to use. Note as Eric Essen wrote that these oils are defined differently. Link to the Amsoil 20w50: https://www.amsoil.com/p/20w-50-syntheti...
Sir_Nerd -
I change my my transmission oil exactly how it showed and yes the spring with the nut on the end came off and I put it right back. Now I have no tension at all in my clutch basically I have no clutch anymore. This is the first time I've taken the inspection plate off during a transmission fluid change. I usually drain it and automatically just put one quart in. What could I have done wrong?
Did you ever figure out what happened?
Jordan -
Tighten the screw will tighten. Clutch.clockwise or counter clock
Derby cover is removed to insure the primary isn't overfilled.
is there not a screw that will drip when filled?
does motorcycle stand in vertical position or on its leg stand during oil level inspection ???
Perfectly level in vertical position!Not leaning on jiffy stand.Have someone help you hold it perfectly level.
also youre not supposed to use the full quart it WILL puke out.
general rule is 28-29oz
What kind of washers are you using in the bolts where the mid controls used to be? My sportster is leaking from those two fixations.
Do I need two separate oils for transmission and engine?
My 08 Sportster custom takes the same fluid for transmission as it does primary fluid because it shares the same cavity but ENGINE OIL CANNOT BE SHARED…
In the words of my local Harley Dealer
You can use the same 20w50 oil in the engine and primary, as long as its jaso ma-2 which is for wet clutch. Also they are 2 separate cavitys thats why u have 2 separate drain plugs. Engine oil is held in the oil tank and primary is in the case.
You can use Amsoil 20w50 Synthetic V-Twin Motorcycle Oil. It is certified for engine, transmission, and primary chaincase lubricant. Manuals will specify gear oil as well (75w90), which is also appropriate to use. Note as Eric Essen and many others wrote that these oils are defined differently. Link to the Amsoil 20w50: https://www.amsoil.com/p/20w-50-syntheti...
Sir_Nerd -
20w-50 vtwin oil DUH. Come on dont be dumb
Did my regular oil n changed oil filter in my 2008 xl883l sporty the did the timing chain case with synthetic. 1 week later redid it with hd regular timing chain oil. That synthetic had me hearing everything.
Después de hacer el cambio de aceite de primaria, colocar la tapa y arrancar la moto la zona de transmidion a comenzado hacer un sólido molesto que chirría y las marchas van algo más de duras, incluso cuesta de colocar el punto muerto esto sucede en marchas cortas pero alargando tercera y cuarta el sonido apfnas se percibe. Alguien podría decirme que sucede, es posible que el embrague este demasiado tenso.
very helpful.i have an 88 1200 sportster i’m changing oil on. the manual just says use h-d sport tranny fluid, ok, never heard of it. every sportster i’ve had uses 75w90 gear oil,or 20w50 V-TWIN formula oil. different than 20w50 auto oil,which doesn’t work with the wet clutch as a bike has. and don’t use 75w90 gear oil for trucks and cars because it may have special additives to reduce friction,which will cause your clutches to slip as those additives are for making slippery. my current oil in it stunk like only gear oil does. so i guess u can use gear oil or 20w50 bike oil in the primary.primary and tranny both use same fluid on a sportster.
hey guys question is anyone knows the diameter for the splined shifter shaft that goes thru the primary cover for a
2004-2005 sportster 883-1200xl custom or point me in the direction of where i can find the specs i read some where that the diameter the bushing goes into is .485in or roughly a 1/2in
my email is ratrod420@yahoo.com
thank you kindly to whom ever has the information
I change primary/trans oil every 2nd oil change. insp. and adjust chain, then i can get back to cruising around, beating up old ladies and snatching their handbags. !
Looking at above comment, do I really need to remove the inspection plate? Don’t want to find myself with no clutch either! Is it sufficient to measure what comes out and replace with same amount rather than remove the inspection plate?
That may get you close but you really should remove the inspection cover so you know for sure that it is not over-filled.
Sir_Nerd -
what about clutch oil?
You can use Amsoil 20w50 Synthetic V-Twin Motorcycle Oil. It is certified for engine, transmission, and primary chaincase lubricant. That's what makes it convenient because you can just buy four bottles of it and you're ready to replace the engine oil and the transmission oil at the same time. It MUST specify motorcycle lubricant. Manuals will specify gear oil as well (75w90), which is also appropriate to use. Note as Eric Essen wrote that these oils are defined differently. Link to the Amsoil 20w50: https://www.amsoil.com/p/20w-50-syntheti...
Sir_Nerd -
I changed my oil and trans fluid about 4 months ago and since I've done that for the first two weeks my clutch shifted nice and easy now it's hard as hell to put it in neutral from first gear or from first gear to second gear from there on it's just fine but not sure what true issue is I'm going to change fluid and trans fluid again and see if any shaving come out on my plug or in fluid has anyone had this problem before and if so does it sound like my clutch plates need to be replaced there is maybe 85,000 miles on it if you can get back I would appreciate it thank you my email is matthewschatz02@gmail.com just looking for some advice but the diagram of top does help me a lot so thank you very much for your help I appreciate it nice to meet you guys
As a supplement to this article highly recommend the Lowbrow video for video of this work:
