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  #1  
Old 19th July 2021
argos587 argos587 is offline
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Sportster/Buell Model: XL 1200 (883 conversion)
Sportster/Buell Year: 1994
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Default 1994, Transmission Noise From Shifter

There is a metal on metal rubbing, rotating, heavy squeaking noise from the transmission with initial movement of shifter arm in either direction. This can be done by lightly pressing or pulling on the shifter to remove the small amount of slack and feel the shifter begin to engage. The noise begins here and can feel a slight pulsation from the shifter arm along with the noise. This also only happens with initial movement, but the actual shifting action seems to be normal when the shifter is fully engaged to shift.

1994 XL Sportster, 60,000 miles
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  #2  
Old 20th July 2021
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Default

Sooner or later you will to pull the outer cover after draining the oil and do a look see.

I'd get the rear wheel off the ground when checking so as turn the motor by hand while looking through tranny door.

Once you find what the problem is. Upload some photos in this thread. I use Imgbb on this site myself for uploading photos.
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  #3  
Old 20th July 2021
argos587 argos587 is offline
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Will share what I find. However, may be a while due to work schedule.
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  #4  
Old 20th July 2021
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Default

The spring washer on the Detent Plate is known to fail, which allows the Detent Plate to wobble on(off) the shaft.

Here's the Sportsterpedia section about the shifter:
http://sportsterpedia.com/doku.php/t...e_the_trapdoor

Taking a look, sooner rather than later, will often prevent on-the-road problems or can prevent greater problems when the initial issue is discovered.

Cover the shaft splines with tape to prevent cutting the rubber shaft seal when removing or installing the primary cover.


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  #5  
Old 21st July 2021
argos587 argos587 is offline
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Default

Thanks for the splines tip. Have stopped riding until I have an opportunity to take a look. Hope it's as simple as the spring.
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  #6  
Old 26th July 2021
argos587 argos587 is offline
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Default

Removed the primary cover and the only thing that seemed a bit out of place was the shifter shaft was wobbly. This is allowing the shifter plate (do not know the actual name) that sits just behind the starter gear to lean into the starter gear. This seems to be the source of the noise and pulsation. The bearing in the primary cover looks fine and no play with the shaft inserted (cover installed). Looks like the bearing in the case housing is worn. Also, noticed some weird debris in the primary area. Looks to be bits of plastic.
Can this be bearing be replaced with out removing the primary?
Any tips on replacing this bearing for the shifter shaft?
Any ideas on what the plastic could be (primary adjuster is smooth with nothing missing)
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  #7  
Old 26th July 2021
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Default

I have spent some time adding information to the Sportsterpedia section on the Shifter Assembly:
http://sportsterpedia.com/doku.php/t...o:transfinal03

You should read over that section carefully. There are also a number of links to XLForum threads that have a greater discussion of the shifter & some issues that have arisen.

Specific to your post:

The shifter assembly bearing does fit relatively loosely in the case cavity.

The shifter assembly is quite wobbly without the cover due to being supported only at one end. With the cover on, the shaft protrudes thru the cover bushing and stabilizes the position of the assembly.

As to Plastic bits - Have you replaced the adjuster shoe before? Left over bits?


Can you post pics of the worn shifter plate? Of the Plastic Bits?


If you remove the primary chain & sprockets,

You should upgrade to the later version Detent Plate, 33656-90A.
Make sure the shifter pins in the shifter drum are tapped home.

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  #8  
Old 27th July 2021
argos587 argos587 is offline
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Here are the pics I have. After some reading I believe the issue is most likely the detent plate spring. Either way, something is allowing the shifter assembly to lean into the starter gear. May need to pull the primary chain and clutch drum assembly to do a full inspection. Will get the new detent plate and e-clip while I'm there.
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  #9  
Old 27th July 2021
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In that fourth picture, is that shift drum pins on the bottom of the primary?
The pins sometimes come out of the drum a little. They are just pressed in.
If they pull out a little, they'll allow the detent plate to lean into the starter gear.
Happens to I'd say most Sportsters with this design.
Most just lightly tap the pins back into the drum.
But if those pins have come out?
Or is that roller bearings or am I going blind?
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  #10  
Old 27th July 2021
argos587 argos587 is offline
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Default

I doubt those pieces are the pins as it shifted just fine in all gears right before pulling the cover and they are flat and seem plastic, not metal. I'll know more once I pull the primary chain & gears for full inspection.
Trying to locate the new style detent plate, but no one seems to have one. Any suggestions to find one (might as well make the improvement now)?
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