My 05 Sportster 1200 wont shift

[jhholl7]

Hello all, my 05 1200 Sportster ran great last season. A month ago I installed a new starter, then changed the engine oil and primary oil. Now it wont let me shift into 2nd or neutral. So, I pulled the primary again and removed the engine sprocket, etc to inspect the shifter peg. Other than that peg being wobbly, everything looked ok. I installed everything back, then drove it and it was shifting normally. After two minutes into ride, it would not allow me to shift out of third (neither up or down gears) . I know I adjusted the clutch cable correctly and adjusted the clutch screw. There is no shift pawl adjustment with my 05, so that's not the issue. Also confirmed that the primary oil level is just under the clutch plates. I hear no irregular sounds. Any idea why this could be happening all of a sudden?

[IXL2Relax]

When you had the cover off, did the shifter drum run thru the gears smoothly?


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[Tomcatt]

Originally Posted by jhholl7

Hello all, my 05 1200 Sportster ran great last season. A month ago I installed a new starter, then changed the engine oil and primary oil. Now it wont let me shift into 2nd or neutral. So, I pulled the primary again...

Exactly what work did you do on the bike before the shifting issues started?

[jhholl7]

When I had the primary cover off, I was not able to turn the shifter peg with my hand. I attached the shift pedal and it did cycle through two gears only. Eventually it cycled through all gears, so I reinstalled the cover and proceed to my test drive. Tomcatt- This all began when I removed the primary cover because I was installing a starter. While I was there I figured why not change the primary oil and the engine oil. I really didnt touch anything other than the bolts that hold the starter, so i'm not sure why this triggered an issue with the gears. I've never had any issues with the gears. 40k miles on bike. This is why I wondered if perhaps I had the wrong primary oil level or adjusted the clutch incorectly. But I reviewed several youtube videos and pretty sure those are correct.

[Tomcatt]

Originally Posted by jhholl7

...I really didn't touch anything other than the bolts that hold the starter...

When issues like this occur after working on the bike, the first things you look at are the last things you did.
Did you have the shifter out? See if the shift return spring is correctly on its' pin.

[jhholl7]

Agreed, that makes sense. I may adjust the primary oil levels a bit to see if anything changes. Curious though, should that shifter pawl be so loose like that? I realize that the cover would keep it from wiggling around once installed, but that seemed a bit strange.

[JB in NC]

Shifting problems can be transmission related or clutch related. To isolate which, try shifting through the gears with the motor off, and just rocking the bike back & forth so the rear wheel is turning the transmission a little. If you can select all 5 gears by this method, the problem is in the clutch (not releasing). Otherwise, the problem is in the shifter, pawl carrier, & etc. in the transmission.

Jim

[Tomcatt]

It sounds like you have a problem with what is the "shifter lever assy" on the parts fiche. There are three springs involved, the coil springs on the pawls and the "spring, shifter return" that all have to be right.

[jhholl7]

I really appreciate the input. JB in NC, I did what you suggested and its shifting fine with the motor off. Then I took it for a spin and she did well until I downshifted to 1, then it wouldn't get neutral or other gears. I shut the bike ok and she shifts just fine again with engine off. Perhaps it is a clutch /grab release issue. Tomcatt, the two springs on my shift lever were intact and strong. Is the sprinter shifter return that black spring deal at the bottom of the pawl? If so, that looks normal and intact on mine as well. -I think i'm going to grab some more gear oil then add a bit and revisit the clutch cable and adjustment. I do have a Barnett clutch pack about 3 years old and had no issues so, hopefully it is something simple like you all suggest. I'll touch back later. -Really appreciate you all

[Tomcatt]

Originally Posted by jhholl7

Tomcatt, the two springs on my shift lever were intact and strong. Is the sprinter shifter return that black spring deal at the bottom of the pawl? If so, that looks normal and intact on mine as well.

No, the "SPRING, SHIFTER RETURN" is on the backside of that assy. It's what makes the shift lever return to center. It has to be installed correctly and it straddles the "PIN, SHIFTER STOP". That's parts fiche nomenclature.