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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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3rd gear, false neutral, missing gear, transmission

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  #1  
Old 1 Week Ago
mattiamike mattiamike is offline
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Exclamation 3rd gear gone only on downshift!

So after a 3 hour highway leg on my 98, 883 sportster, I've developed an issue engaging 3rd gear.

(Any input you guys may have is very much appreciated, though I'm more posting as an informative thread for you guys)

When the engine is hot, downshifting into 3rd, I roll as though I'm in neutral, if I VERY lightly click the shifter down again, it goes into 3rd and I get my engine braking.
This doesn't happen on upshift, it doesn't happen in other gears, just 3rd, on the downshift.

I once had the opportunity to pull over with the transmission in this "twilight" gear, this is strange... I came to a stop in what should be 3rd, let out my clutch slowly and it didn't move, so I let the clutch out completely and looked down to listen to the transmission, all of a sudden WHAM! into gear it went, without me touching the shifter or the clutch. Strange...

I'm an employee at a harley dealership, I've obtained some very useful info and documents from my peers. I feel confident that it is a shifter detent issue, and here's why.

Upon removing the primary cover I have noticed that behind the starter gear, sits the detent plate, without removing the clutch, I can feel that the detent plate has alot of movement in it, where I assume it should be solid and rotate only on one axis.

Tomorrow I will remove the clutch and engine sprocket and reveal the issue, I will post my findings then!
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  #2  
Old 1 Week Ago
John Harper John Harper is offline
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Look forward to your findings. Good luck!

John
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  #3  
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From another current thread:

Here's the detent info in the Sportsterpedia - It refers to this thread (http://xlforum.net/forums/showthread.php?t=198227):
http://sportsterpedia.com/doku.php/t...e_the_trapdoor

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  #4  
Old 1 Week Ago
mattiamike mattiamike is offline
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Update!

Found the source of the issue. It was NOT the detent plate, however that is an issue ill address before putting it back together, the clip originally holding the plate on, has weakened, causing the detent plate to wobble around and make contact with the starter gear, it is mangled, but still functional.

The real issue is the shift barrel, on the number 6 fork trench, there seems to be some pitting and/or scoring on the edges of the divot coming out of 3rd and into 4th, causing the pin (and the shift fork) to get hung up at the spot right between 4th and 3rd, but not between 3rd and 2nd. Viola!

This is all a theory, will update again when parts arrive at work some time in the next 4 weeks.
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  #5  
Old 6 Days Ago
Andy56 Andy56 is offline
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I don't have an answer and my bike is much newer but on my bike it is a different experience selected 3rd gear going up or down compared to other gears.

There is mostly what I will describe as a noticeable click not present with any other gear.
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