The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Drivetrain > Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Notices

Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

Active Threads
0 Do you Run a Fuel Filter?
Last Post: Highly-Dangerous
Posted On: 1 Minute Ago
Replies: 26
Views: 5,932
0 Heads Up Display in your Helmet
Last Post: IXL2Relax
Posted On: 2 Minutes Ago
Replies: 0
Views: 1
0 What did you do for your sporty Today?
Last Post: boomerguy
Posted On: 8 Minutes Ago
Replies: 7,180
Views: 1,053,957
0 Keep & Kill
Last Post: Crusty
Posted On: 28 Minutes Ago
Replies: 18,322
Views: 1,088,302
0 Gear Spacing Question
Last Post: ferretface
Posted On: 30 Minutes Ago
Replies: 0
Views: 1
2 My 1275 Hammer Conversion..
Last Post: Highly-Dangerous
Posted On: 40 Minutes Ago
Replies: 178
Views: 17,695
3 Ironhead Pictures Thread
Last Post: eddie XLX
Posted On: 42 Minutes Ago
Replies: 2,026
Views: 843,043
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 43 Minutes Ago
Replies: 23,026
Views: 2,346,427
0 Hot Chicks on Hot Bikes
Last Post: trainman
Posted On: 49 Minutes Ago
Replies: 11,193
Views: 2,216,754
0 stumble
Last Post: steve lewis
Posted On: 55 Minutes Ago
Replies: 17
Views: 525
0 New oil tank
Last Post: IXL2Relax
Posted On: 1 Hour Ago
Replies: 24
Views: 2,907
0 Most common rattle locations?
Last Post: AZbiker
Posted On: 1 Hour Ago
Replies: 10
Views: 216
0 Hello from Holland
Last Post: IXL2Relax
Posted On: 2 Hours Ago
Replies: 15
Views: 190
0 How Indian Makes 43% More Power than Harley-Davidson
Last Post: BKB
Posted On: 2 Hours Ago
Replies: 48
Views: 1,173
0 Reflectors...Yeah, or Neh
Last Post: ron521
Posted On: 2 Hours Ago
Replies: 186
Views: 45,950
0 Halloween 1250 Conversion
Last Post: NLXL
Posted On: 2 Hours Ago
Replies: 12
Views: 266
0 Hi everyone
Last Post: Steve9
Posted On: 3 Hours Ago
Replies: 15
Views: 446
0 Wanted (Buell Inlet Manifold)
Last Post: gusm2
Posted On: 3 Hours Ago
Replies: 6
Views: 255
0 Hello everyone
Last Post: Highly-Dangerous
Posted On: 4 Hours Ago
Replies: 13
Views: 228
0 Greetings from Venezuela
Last Post: Highly-Dangerous
Posted On: 4 Hours Ago
Replies: 19
Views: 772
0 whats going on?
Last Post: Highly-Dangerous
Posted On: 4 Hours Ago
Replies: 21
Views: 701
0 Hello from LA area
Last Post: Highly-Dangerous
Posted On: 4 Hours Ago
Replies: 13
Views: 448
0 Starter problem
Last Post: sportsterdoc
Posted On: 4 Hours Ago
Replies: 1
Views: 97
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 4 Hours Ago
Replies: 48,577
Views: 7,857,459
0 Strengthening 73 rear shock structure
Last Post: Beary
Posted On: 4 Hours Ago
Replies: 11
Views: 336
0 Snippets
Last Post: ChinCactus
Posted On: 4 Hours Ago
Replies: 267
Views: 27,920
0 Late XLCH front end - any good?
Last Post: 45Brit
Posted On: 5 Hours Ago
Replies: 8
Views: 240
0 primary register screw
Last Post: Tomcatt
Posted On: 5 Hours Ago
Replies: 5
Views: 210
0 Able to Ride with Parkinson's Disease
Last Post: Desertfox
Posted On: 5 Hours Ago
Replies: 4
Views: 179
0 One More Ohio Meet & Eat?
Last Post: Bow only
Posted On: 5 Hours Ago
Replies: 25
Views: 1,321
More...
Members Birthdays
black pearl (76), SDREDD (59), pig (57), BonRu (55), wandawells42 (51), cbass (47), ssm7530 (45), HawkeyeTX, SxysCowboy (37)
Reply
 
Share Thread Tools Display Modes
  #1  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
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 15:28.. Reason: title change
Reply With Quote
  #2  
Old 8th September 2019
Davo_137's Avatar
Davo_137 Davo_137 is offline
XL FORUM TEAM MEMBER
 
Join Date: May 2018
Location: Central Queensland, Australia
Posts: 646
Sportster/Buell Model: XR1250X
Sportster/Buell Year: 2010
Reputation: 1365121
Davo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond reputeDavo_137 has a reputation beyond repute
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.
Reply With Quote
  #3  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
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.
Reply With Quote
  #4  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
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.
Reply With Quote
  #5  
Old 8th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
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.
Reply With Quote
  #6  
Old 13th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
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.
Reply With Quote
  #7  
Old 15th September 2019
Hellbent_4 Hellbent_4 is offline
Harley Engineer
 
Join Date: Aug 2015
Location: On lake Erie
Posts: 336
Sportster/Buell Model: XLH883 Hugger
Sportster/Buell Year: 2002
Reputation: 130211
Hellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud ofHellbent_4 has much to be proud of
Default

Well, 180 miles today and only a minor primary adjustment.
So far so good.
Reply With Quote
  #8  
Old 15th September 2019
Ireeman's Avatar
Ireeman Ireeman is offline
Asgardian
 
Join Date: Jul 2008
Location: Deck of Me boat
Posts: 8,432
Sportster/Buell Model: 883r
Sportster/Buell Year: 2003
Other Motorcycle Model: Chris Craft 32
Other Motorcycle Year: abov
Reputation: 8866250
Ireeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond reputeIreeman has a reputation beyond repute
Default

Well done mister, well done.
__________________
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT +1. The time now is 19:43.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC