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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
Hellbent_4 Hellbent_4 is offline
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Sportster/Buell Model: XLH883 Hugger
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Default Shifter Went Limp

Note: This is on an 02 frame mount engine. Other series have different shifter layouts.

I was out collecting bugs on my new air cleaner today and as I pulled into the driveway, I shifted down to first and the shifter stayed down.
I pulled up to the garage and toed the shifter up and down and the gears worked fine. It just wouldn't return to center.
Up on the lift and proceeded to dump the quart of oil that I had changed last week out on the floor. 200 degree drain plug and oil, small space and it fell in the funnel and clogged the hole. At that point I just sat back and sighed. (Actually there was a lot of swearing, too)

Pulled the cover and sure enough the spring broke. Found the piece in the cover.
Part #30 on this page: http://partsfinder.onlinemicrofiche....TER%20ASSEMBLY

So, the question is: can the shifter assy come out without pulling the clutch/chain/pulley assembly?

ETA: I just found out you can't change the main title for some reason. Only the title over the post.

Last edited by Hellbent_4; 8th September 2019 at 16:28.. Reason: title change
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  #2  
Old 8th September 2019
Davo_137's Avatar
Davo_137 Davo_137 is offline
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Default

I have read some have managed to replace the shifter shaft without touching anything else, unfortunately I am not as gifted as these puzzle solvers and had to slide the clutch assembly out a little.

So to answer your question, no you don’t need to remove everything in there to replace the shifter shaft.
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  #3  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
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Default

I was looking at the Sportsterpedia and it looks like I should be able to pull the pawl spring and lift the pawl up to clear the clutch basket.
I'll give it a shot tomorrow.

ETA: no joy on getting it out. I got the pawl spring off so I can rotate it but now it hits the mounting plate stop and with the mounting screws in the way everything is kind of in everything elses way.
Checking at the stealership later.
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  #4  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
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Default

Well, dealership says it's gotta come out.
I could drive to Avon and get the spring, otherwise wait a couple days.
I picked up a 1 3/16" socket and a couple of the primary seals.
I figure I might as well change them while I'm in there.
Now lets see if my little pancake compressor has enough guts to run a 1/2" impact.
Already made the aluminum brace.
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  #5  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
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Default

Well, everything came off easy enough.
The detent ring clip broke when I took it off.
Gutted primary:

I still don't know how that bug vaporized itself on the back side of the horn.

Guts. You can see the broken end of the spring on the right above the detent ring.

On the plus side, no grenade rivets.
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  #6  
Old 14th September 2019
Hellbent_4 Hellbent_4 is offline
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Default

I got it back together and it works. Haven't ridden it yet but the clutch disengages and the shifter works.
I pulled in the clutch and started it in gear, the bike didn't jump. Eased the clutch out to check engagement and it seems to be good, I even held the front brake and gave it some gas.

Next project: blackout the engine.

==============================
A couple of issues I ran into:
-As someone had posted in another thread (thank you whomever you were ), the pins on the shift drum had drifted out a bit.
I tapped them back using a drift punch.

-The drill bit / third gear adjustment didn't work because the side of one of the pins was protruding into the hole you measure through. I tightened the plate back down where the nut marks were on it already and then checked it by putting it in first and running the gears. Seems to be OK so far. I'll know for sure when I get to put some miles on it.

-The large snap ring that holds the plunger in is a pain (I need a larger ring pliers.) It came out with a couple little screw drivers. To put it back in I wound up setting one end in and working the rest in.

-200 FT-LB is a LOT and my wrench only goes up to 150. (I saw on ebay the torque multipliers and if I have to go in again, I'm getting one.) I torqued it to 150, gave it an extra oomph with a 1/2" breaker bar and hit it for two seconds with a 1/2" air wrench. Here's hoping.

-Checking the clutch disengagement requires the bike being on the ground and pushing back and forth unless you can overcome the clutch drag moving the rear tire.

==============
Tech tips:
(Note: This is on an '02 frame mount so YMMV)

-When you remove the drain plug, let the plug drop, then put the funnel under it. On the Crafstman lift the plug is directly over the support and leaves little room to work. Letting the oil cool some would probably have been a good idea, too (Shits hot, yo). Or make a screen an inch or so above the little hole in the funnel. You don't have to go fishing in the oil for the plug that way, too.

-The 1/4" aluminum plate works great to lock the gears.

-A little pancake compressor does have enough ass to get things apart.

-When you loosen the chain adjuster turn both the allen and the wrench and unscrew them together. That way they are nearly adjusted when you reassemble.

-A new derby o-ring makes putting the little bastige' back on much easier. (17 year old bike and the o-ring had swelled so it would pop out of the groove)

-The shifter seal is cheap, if it's older change it while you are in there. It keeps the dribbles down.

-The primary goes over the shift lever easier with a little CW/CCW twisting motion. Gently so the seal doesn't get damaged. Others have suggested tape on the shaft.

-The primary gasket is easier to work with if it is kept flat (metal sandwich, I reused mine) and stays on the dowel pins. When you are installing the cover you align the shifter shaft first, get the chain up and over the adjuster, make sure the gasket is in place and then set the cover on the pins.
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  #7  
Old 15th September 2019
Hellbent_4 Hellbent_4 is offline
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Default

Well, 180 miles today and only a minor primary adjustment.
So far so good.
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  #8  
Old 15th September 2019
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Ireeman Ireeman is offline
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Well done mister, well done.
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