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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 28th August 2019
Pro1 Pro1 is offline
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Default HELP!! Won't shift

Hi all. New here. I Need help!!! I have a 95 1200 Sportster and I can't get it to shift past 2nd. I just replaced the 5th gear output shaft and put in a new clutch pack and primary chain while I was there. After I re-installed the transmission I could turn the shift drum by hand easily. I lined up the shit pawl per the Harley book and used a thin washer and e-clip instead of the factory clip on the detent plate. all else installed per the book. Buttoned up the primary, filled w/ oil and fired it up today and can't get the thing past 2nd gear. Any ideas before I tear it back apart????
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Old 28th August 2019
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Welcome to the XLForum.

Quote:
Any ideas before I tear it back apart?
Any binding of sifter?

Sounds like you need to open it up.

I'd put it back together in 3rd gear??
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Old 28th August 2019
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Cool

I'm thinkin' the eccentric screw on the shifter pawl is not properly adjusted.....did you adjust that in 3rd gear??did you insure the eccentric portion of the screw is at 12 o'clock and not at 6??

sounds like you need to open it up......
I'd put it back together in 3rd gear

carry on

Ww
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Old 28th August 2019
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Cool your first post

oh, and welcome to the forum from sunny New England, home of the worlds largest superbowl ring collection

all the help you will ever need for your Sporty is here, look around, don't be shy.... there's even an introduce yourself area

carry on

Ww
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Old 29th August 2019
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Default

Thanks for the welcome and suggestions.
Racerwill - I bash on New England all the time in good fun but I have to give credit where credit is due. They've been a solid team for years and deserve the rings they have..... Dam that hurt......
I set the shift pawl up with the drill bit size called out in the factory manual (#32) w/ the trans in 3rd gear. Not sure what you mean by "eccentric screw". The 95 shift pawl is held on and adjusted by two poly lock nuts on studs in the case. The shit pawl has slots to allow adjustment between the shift fork and drum pins. I'll tear it back down this weekend and re adjust the clearance - may have to tweak it a bit.
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Default

Here's the Sportsterpedia section on the 5-speed transmission:
http://sportsterpedia.com/doku.php/t...o:transfinal03

Have a look around...

Follow the procedure in the manual carefully...

Do you have the upgraded Detent Plate - 33656-90A ???

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Old 30th August 2019
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Cool

Quote:
Originally Posted by Pro1 View Post
Thanks for the welcome and suggestions.
Racerwill - I bash on New England all the time in good fun but I have to give credit where credit is due. They've been a solid team for years and deserve the rings they have..... Dam that hurt......
I set the shift pawl up with the drill bit size called out in the factory manual (#32) w/ the trans in 3rd gear. Not sure what you mean by "eccentric screw". The 95 shift pawl is held on and adjusted by two poly lock nuts on studs in the case. The shit pawl has slots to allow adjustment between the shift fork and drum pins. I'll tear it back down this weekend and re adjust the clearance - may have to tweak it a bit.
sorry, my fault, the last 2 transmissions I went into were both Bakers, and they use the eccentric screw.....I remember on the HD 5 speed there's a small arm all the way near the case that rotates on a shaft and held in position by a very small spring...... if that spring comes off or that little arm is upside down or flipped over it won't shift up

carry on

Ww
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