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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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  #11  
Old 10th October 2008
nate454ss nate454ss is offline
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Replaced both first gears and took care of the problems and the wife is happy. Was a pretty easy fix, took about an hour and half to do the job. thanks everyone
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  #12  
Old 10th October 2008
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beuz beuz is offline
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An happy rider is the best "thanks" I could expect....
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You live more in 5 minutes flat out on a bike like this than most people do in a lifetime...
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  #13  
Old 10th October 2008
Fe Head Fe Head is offline
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Again - excellent pictures -worth at least 1K of words.

The jumpimg in and or out of any gear is primarily due to the condition of the leading and trailing shoulders on each dog pair.

As the shoulder(s) become rounded off from slow shifting or grinding shifts the angle of repose (zero rake angle) drops away from a pure 90 degrees. This slight angle will alllow the radial forces (i.e. torque) to be converted to axial or side forces that can not be resisted by friction or the shifter fork and pawl dedent spring.

In high performance e.g.turbocharged engines or other racing applications the builders will often do a " negative rake" cut or machining so there is a side or lateral force that pulls the dogs togther and insures - for the most part - that there is no chance of a gear jumping either i) out during acceleration or ii) out again while in de-acceleration from down shifting.

Gear popping only gets worse with time and with each time it jumps - never better. That is why, not unlike voting was in Chicago in the 1930's, it is good to " shift often and shift hard".

I hope this helps to explain the most common cause of gear jumping when the adjustments are correct.

Cheers;
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  #14  
Old 10th October 2008
joshinak joshinak is offline
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Thumbs up Great explanation

Thanks, Fe Head. I will have to read it a few dozen times to completely understand. I think I will start with the clutch adjustment first. Then look at the warped plate if it doesnt help and then pull the tranny if all else fails. I better go get busy. The snow all melted today. We have wet but ice free roads. I'll take it for a test ride before winter sets it for good. Its hard to feel the gear jump when the roads are icy. Hard to beleive a 5000 mile bike is having these problems. Thanks for the explanation
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  #15  
Old 23rd October 2008
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Quote:
Originally Posted by beuz View Post
I HAD TO REPLACE MINE....(the one on the pic).
here are all the part numbers you'll need :




No differences in the gear box between 1996 and 2003.
Quote:
Originally Posted by nate454ss View Post
Replaced both first gears and took care of the problems and the wife is happy. Was a pretty easy fix, took about an hour and half to do the job. thanks everyone
Which parts exactly did you replace?
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  #16  
Old 24th October 2008
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My gear first-countershaft (P/N 37763-89A), as shown the the page 1 of this thread.
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  #17  
Old 24th October 2008
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Quote:
Originally Posted by beuz View Post
My gear first-countershaft (P/N 37763-89A), as shown the the page 1 of this thread.
Thanks buddy
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  #18  
Old 24th October 2008
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aswracing aswracing is offline
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Quote:
Originally Posted by beuz View Post
[B]
No differences in the gear box between 1996 and 2003.
Second gear on both the mainshaft and countershaft changed in '00, as they changed the second gear ratio.

Here's some pics of worn dogs, this is what mates with the gear pictured above:




Last edited by aswracing; 16th August 2017 at 16:09..
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  #19  
Old 24th October 2008
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Quote:
Originally Posted by aswracing View Post
Second gear on both the mainshaft and countershaft changed in '00, as they changed the second gear ratio.
Thanks for the info and the pics.
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  #20  
Old 25th October 2008
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My bike shifts fine except sometimes when going from 1st to 2nd it pops back into neutral. Should I be using more force to kick it solidly into 2nd or do you think my gear needs to be replaced??
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