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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #1  
Old 2 Weeks Ago
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Chewbaca Chewbaca is offline
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Default Tranny or clutch? Can't find the issue

Greetings,

'96 883 with a 1200 top end.

A couple weeks ago, while warm, the bike did not want to shift, as in the lever was completely stuck in 2nd, while at stop light.

I released the clutch a bit to lurk forward, and it engaged and was able to go on my way. I thought I'd adjust the clutch and did so.

Bike was fine for a few more 30 mile trips through traffic, not really high rpms. But recently I was cruising at about 75 mph, and when I took the off ramp to exit the fwy, i started hearing a rattle on the primary side. It got a little worse when I tried downshifting, but it essentially did not want to disengage from 5th gear. I shut the bike off, and was able to shift down to neutral.

Started it back up, and was on my way again. It's done this a couple times and only after slowing down from high speed.

Opened up the primary, and didn't find any broken pieces of metal in oil or drain area. Am I needing a new clutch? Or is something going on with shift pawl? Not sure what exactly to be looking for, as I haven't really had to get this deep into the bike.

Any suggestions or things to look for would be greatly appreciated as this is my daily commuter to and from work.
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  #2  
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It sounds like the clip came off of the shifter detent. I have that job coming up in the next week or two on mine

2002 883 Hugger
Hammer 1275
Hammer "Smash" head porting
Mikuni HSR 45
560 cams
BDL lockup clutch
Thunderheader exhaust
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do not think it to be clutch unless the spring plate is snafu'd
take a look at the detent plate. when mine started doing this, the cheesy keeper on the plate failed and allowed the plate to battle with the clutch basket and pawl mechanism. this is a known issue.
when mine started doing this, replaced plate and new design for retainer and set using drill bit method and all is good.
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Thank you gentlemen. The detent plate is located on the shift lever mechanism?
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Quote:
Originally Posted by Chewbaca View Post
Thank you gentlemen. The detent plate is located on the shift lever mechanism?
Right behind the clutch ring gear.

2002 883 Hugger
Hammer 1275
Hammer "Smash" head porting
Mikuni HSR 45
560 cams
BDL lockup clutch
Thunderheader exhaust
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