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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 17th October 2012
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Default Lost 2nd gear, help!

So I got out for a great ride yesterday, but right at the end it seems like my neutral annunciator light was not reading accurately (the bike would be in neutral, but no green light), and my shifter felt funny, like it wasn't giving the feedback I'm used to. I think I've lost 2nd gear! Where do I start?? 2002 883R, stock except for Stage 1.

Thanks.
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  #2  
Old 17th October 2012
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Sorry nobody's chimed in yet. I'll start; starting with the simple stuff before you tear your transmission out---The search bar at the bottom left is your friend, the one up top is crap. Just in case you didn't know this. Next is the shifter arm, making sure it's not rotating on the shaft. See? Simple stuff first. How about the other gears? Does it shift through all the others? I see two possibilities, and I'm sure someone will correct me if I'm wrong or left something out, the shifter pawl bearing or shaft is allowing enough movement that it isn't fully engaging, or the dogs on the gear are wore out and you need to replace the gear. If it were the dogs, it would go into second but slip out, I think. My guess is when you get the transmission out, look at the pawl carrier bolted to the trap door.
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  #3  
Old 17th October 2012
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Default

Shifter arm is secure, and it does seem to shift thru the other gears. No grinding or noises, just no 2nd gear and a weird neutral point with no positive feel/green light. I'll look at the FSM and see what's involved; here's hoping for an easy fix!
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Old 17th October 2012
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Default

Just be glad you can take the transmission out without splitting the cases. Sounds like you're going to be doing just that.


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  #5  
Old 18th October 2012
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Default

Follow-up:

So it turns out that it WAS th shifter detent retainer clip. It had disintegrated, and the detent wheel wasn't engaging the pins properly. I took a few pics, hopefully they will help someone in the future.

Here's the primary cover off, exposing the main sprocket, primary chain & clutch assembly. I let the oil drain overnight before taking it off.



It didn't take long to find this... the faulty clip.



All this work for a stoopid $2 part! At least it wasn't in a million tiny pieces.



I used a trick posted by another XL Forum member; $5 for a 4" brass hinge and voila! The sprocket nut and clutch nut were off. Sweet! The hinge immobilizes the gears, and you can reverse it for reassembly (or for the reverse threads on the clutch).




I used 2 5/16 e-clips to reattach the detent wheel...







... and then buttoned her back up. Everything is back to normal! I used this opportunity to adjust the primary chain, and the clutch. I only wish that I had been able to remove the pawl pins and apply some red loctite. Oh, well- this should hold for a few thousand miles. If anybody has any questions, feel free to PM me.
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Old 20th October 2012
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Bump for pics. Enjoy
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Old 21st October 2012
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That was a great follow up! I'm glad you got it figured out, and extremely glad it was inexpensive ! Way to go, man!


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Old 21st October 2012
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I must've missed this one. Those detent clips are another example of the factory saving a penny. Glad you got it worked out.

Ride On!
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Yep, I'm hoping that he e-clips last longer than the factory clip... that one ony held on for 6800 miles! I realllly wish I'd been able to remove and loctite those pawl pins.

One thing I'll say is that I'm no longer afraid of opening the primary case. Also, incredibly- no oil leaks so far!
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Old 21st October 2012
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Those pins will stay where they belong as long as the retainer clip is there. E-clip should be fine. At least you know the drill the next time.

The ultimate fix is a Baker shift drum, which uses a screw to hold the detent plate on.

Quote:
Originally Posted by Rv7garage View Post
Yep, I'm hoping that he e-clips last longer than the factory clip... that one ony held on for 6800 miles! I realllly wish I'd been able to remove and loctite those pawl pins.

One thing I'll say is that I'm no longer afraid of opening the primary case. Also, incredibly- no oil leaks so far!
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