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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 8th September 2019
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vtwinlynne vtwinlynne is offline
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Default Mystery clutch / trans problem.

1993 XLH 1200 with only 16,000 miles on the clock.
~~
Riding home from work I was just changing gear and accelerating from about 10mph and.. no drive! This has happened to me once before when the belt snapped but this time the clutch cable had developed excessive slack at the lever and of course I had no tools with me so I couldn't readjust it.
I initially assumed the cable must have broken at the clutch end but when I removed the primary and checked it over it was good. It has a bolt on light clutch device (not the replacement ramp) fitted by the previous owner but that looked good too.
I put everything back together and adjusted the clutch as per the service manual but it won't change gear. The lever clicks through the gears but there's no actual engagement. There was no debris when I drained the oil either and the parts of the shift mechanism I can see still have their springs.

I checked the threads on this forum and I thought it might be the start of the dreaded grenade plate dying so I took it all apart again and fitted an extra plate kit from Energy One. Mind you, the original plates were perfect as was the spring plate. Once back together still no gear engagement. Any ideas? I'm worried that I'm thinking it's a clutch problem when it might be a transmission problem. What would have caused the clutch cable to lose tension like that? I wasn't doing anything outrageous, just negotiating a quiet country road. (Honestly officer...!)
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  #2  
Old 8th September 2019
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Check front pulley, might be loose..?
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  #3  
Old 8th September 2019
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Did you check the ramp bearings on the clutch? Could also be the detent plate on the transmission. It is held on my a very flimsy circlip that is known to come off.
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  #4  
Old 8th September 2019
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Thanks! I'll check those. The ramp bearings are okay I know but the detent plate I haven't checked or the front pulley.
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Old 9th September 2019
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If you loosen all the clutch adjustments the clutch should lock up.
At that point put it in gear and try to move the bike.
If it doesn't move then your transmission is probably OK and something is the linkage gave out.
If it does move with no resistance then that would be bad.

If your shifter is clicking then the detent plate is still on and attached to the shift drum.
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Old 10th September 2019
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Here's the Sportsterpedia section on the Clutch:
http://sportsterpedia.com/doku.php/t...vo:priclutch01

and the Shifter components:
http://sportsterpedia.com/doku.php/t...e_the_trapdoor


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  #7  
Old 10th September 2019
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Quote:
Originally Posted by Hellbent_4 View Post
If you loosen all the clutch adjustments the clutch should lock up.
At that point put it in gear and try to move the bike.
If it doesn't move then your transmission is probably OK and something is the linkage gave out.
If it does move with no resistance then that would be bad.

If your shifter is clicking then the detent plate is still on and attached to the shift drum.
With the clutch adjusted as normal and put into gear I can move it easily as if it was still in neutral but I'll try what you say and report back. No clicking or strange noises either.
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  #8  
Old 10th September 2019
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vtwinlynne vtwinlynne is offline
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Default

Here's the Sportsterpedia section on the Clutch:
http://sportsterpedia.com/doku.php/t...vo:priclutch01

and the Shifter components:
http://sportsterpedia.com/doku.php/t...e_the_trapdoor


Thanks, I'll do some more reading
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