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  #1  
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Default Transmission Issue or clutch?

Okay so I have a 76 xlh its now running strong and healthy.

Now that I'm able to road test it I'm having an odd issue and I'm not a Guru and at the moment stabbing in the dark. I'm hoping someone here can give a direction or just an idea that I haven't come to yet.

(Clutch cable has been Adjusted and feel right)

*So while bike is running I can shift into (1st) while holding in the clutch, not all the time but sometime it pops back into (Neutral) while releasing the clutch.

*Some times it only pop back into (Neutral) while under load and if / when is sporadic.

*Once off and riding the bike pulls and is strong while is (2nd) or (3rd) no issues not popping out of gear or slipping, Have not made it to (4th) yet. I do not feel any issues in any gear other than (1st) no odd feeling or sounds... Nothing to cause alarm.

*While riding if down shifting into (1st) the bike act normal. If and when throttling up while in (1st) I experience two issues. either it will pop into (Neutral) or it will Surge while pulling at speed. It feels as if its being shifted from (1st) to (Neutral) and back with moment of time between each "shift" or "slip" of the clutch!?!??

Now I planned on replacing the clutch already and have ordered a few days ago.
Reason for this post is to see if it could be anything else?
Should I be searching for a new transmission?

I drained the primary last night and noticed a large amount of shaving on the drain plug magnet. tonight I will open up the primary and inspect.

Now this bike had been sitting for some time before I got it. Once I got it running again I did warm the bike and idle it in each gear with the clutch unengaged to allow the clutch to break free.

Thanks in advance to any and all info, help, or comments
j
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Is your shifting linkage sloppy? Maybe there’s enough slop that it’s not allowing the gear dogs to engage their mating gear’s pockets for 1st gear. That’s best case scenario. If you are already going to have the primary open, I suggest you go the next step and pull and inspect the transmission. It’s the #1 thing that will wreck your bike. I suspect there is either significant wear in the gear dogs/pockets or the internal portion of the shifting mechanism. No fear, we can help you through it.
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While you have it open up check the end play on both shafts.
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yep,it's not the clutch.
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Time to pull the trans out and rebuild it.
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+1 for Doodah.

Going up through the gears the dogs are loaded on the front faces. Going down they are loaded on the back faces. That's why it jumps going up and not down.
Worn anc chipped dogs will do that, a clutch won't.

there are of course few other things that can cause this.

A bent fork.

Incorrect spacing. (This can happen a couple ways. If the trap door comes loose - that has happened to me. Excess wear on the trap door in the C/S area. That also happened to me.)

In any case you are going to have to pull the gearbox to correct the problem.

A close examination of the metal on the plug will tell you things.

Wear on the door is dull grey dust. Shiny brass is a shifter fork (won't show so much on the plug as it's not magnetic). Nice shiny stuff you really don't want. That's gear/shaft metal.
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If you can start out in 2nd gear without any of the issues that using 1str gear produces, and no other gears have a problem, THAT sounds like an issue with 1st gear and not a clutch problem. At least the transmission is separate on a Sportster of that age.
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So i pulled the primary cover of and inspected.
Inside look pretty clean. I'll have to pull the clutch apart as well as the primary drive before i can start really inspecting the trans.
I did notice one thing that may explain or hint to what might or maybe causing my issue.
You'll all have to school me on fitment for these different 4spds
I noticed that my trans plate has the notch from a later year trans. The notch for the left side shift arm.
I have a 76 the year before the case /shift rod change.
Mine is still right hand shift rod (thought the case)
I was "told" so correct me if I am wrong that the 77 and up trans don't interchange with the 76 and down models.
Could this be the cause of my problems or am i completely wrong. I am willing to except either anwser!
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Not much difference in the trap door you have and what it would’ve came with in ‘76 except for the notch. There is a small difference in the pawl carrier and shift cam axle between ‘76 and ‘77, but it is minor. No difference in gears and shafts between the two years.
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Awe good to know...
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