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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #1  
Old 4th October 2009
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GophersAndCheese GophersAndCheese is offline
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Default Ragerbuilt Jockey Shift for 04+

Ragerbuilt is now making bolt-on kits for 04+ (in spite of their website that still only shows the kit fitting up to 2003s without modification). I bought one and got it yesterday (it took a week for the black powdercoat). Walt has been great to deal with and I am excited to get the kit installed.

The difference between the '03 and '04 versions is how the bracket attaches to the bike. Instead of it attaching by two primary cover bolts, it seems to attach via the primary chain adjustment bolt on the bottom of the primary.

I've run into a bit of a roadblock with this...

I sent Walt a note asking for clarification (since the instructions included were still for the 2003 version), but does anyone here have one of these newer kits?

My concern is that it seems to attach between the primary and nut on the primary chain adjustment bolt. However, that nut has a nylon top that appears to create a seal. If I mount the bracket in between, I fear that it could leak causing a host of problems. If I don't mount it that way, it doesn't seem I have enough thread to attach the bracket between the nut and another nut (not included in the kit) and also worry that this will not be very strong and could break. Perhaps there is some sort of nylon washer or o-ring I could buy and put between the bracket and primary, but I am not sure.

I am also a bit worried because I have backed the primary chain adjustment bolt all the way down to get the nut off and would like to know whether I can feel relatively confident simply screwing it back in to where it was (I took pics so I know the number of threads that were showing) or whether I need to completely drain the primary and take the cover off to get it right.

I have the kit about 90% installed but am stuck on this last part. Please let me know if you have any advice. I'll post Walt's reply too in case anyone else is interested. I will also post some pics when it's all done too. Thanks!
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  #2  
Old 4th October 2009
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Oli1200 Oli1200 is offline
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Pics would definitely help. I'd also just like to see the '04 setup from Walt. I run the Labriola setup.
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  #3  
Old 4th October 2009
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Went back down to the garage to mess with the bike a bit more and when I tightened the nut, the bolt stayed in place. At this point, I am 99% sure I have to drain the primary and pull the cover so that I can access the parts I need to to get it adjusted properly. Good news - I was due for my 25K maintenance anyway and will feel a lot better if I know my primary chain is adjusted properly. Bad news - unless I messed something up in the installation, this is proving to be anything but bolt-on. I'll get some pics posted so you guys can see what I'm talking about.
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  #4  
Old 4th October 2009
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Here is a picture of what is included with the '04 Kit (I opted for the powdercoated version):

Includes shift handle, bracket, cable, screw & washers for attaching cable to old shift lever, gasket?, sticker, and instructions (unfortunately not updated for '04).

I also bought a new o-ring at my local dealer for where the shift cable meets the primary (not included in kit) since the service manual recommends discarding the old o-ring. I suppose I could have re-used the old one.


On to the issues I am having... The bracket has one hole and that fits the primary adjustment screw. Here is the primary adjustment screw before I removed the nut:



The nut was very tight on the bolt so they moved together. It was only when the bolt could not go any farther, that the nut came off:



Here you can see the top of the nut where it has a nylon top to seal itself against the primary:



Here you can see where I put the bracket between the primary and the nut (not fully tightened yet) but you can see how the nut is moving up the bolt but the bolt is stationary (meaning my primary chain is definitely not adjusted properly).



... and here is a shot farther away (sorry for the crappy lighting in my garage) where you can see the kit about 90% installed. The bracket is not secured, my primary chain is probably seriously out of adjustment, and the cable is not secured to the old shifter arm yet (it will need to be trimmed too). You can however see the hand shift and the red & silver aluminum shifter that I feel matches my tank really well. It should all look pretty cool when it's done and I'm very excited to try it out. However, it has become very clear that won't happen today.



Unless anyone has a better idea, my plan is to drain the primary and pull the cover off so I can get the adjustment done properly and get the bolt (and therefore the shoe) in the right position with proper tension on the chain. I was really hoping it wouldn't come to that.

I'll eventually get some good outdoor pics when it's all finally done.
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  #5  
Old 4th October 2009
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Not sure why you really need to drain and adjust the primary with the cover off..your just complicating the whole process IMHO


If you get up under the bike..that stud is made to use an allen wrench to adjust from the bottom..The nut just tightens the stud when finished keeping the chain in position as the nut gets tightened to the primary cover itself..

The stud and nut do serve a purpose..making it impossible to adjust the primary chain without them..the allen key makes it easier to fine tune before you lock everything down..

Last edited by xllent01; 4th October 2009 at 23:47..
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Old 4th October 2009
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Does that bracket just serve to keep the cable in line? Could you run the cable without the bracket?

Yeah, the primary chain is adjusted with the bolt that has an allen wrench end, the nut keeps it in place.
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Old 4th October 2009
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As has been said, there is no reason to remove the primary cover. Just loosen the locking nut and use a 1/4" allen wrench to adjust the plate. Then just tighten up the locking nut to 20-25 ft lbs.
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  #8  
Old 5th October 2009
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You guys rock. Thanks for the suggestions! I am going to try putting the stud back to where it was in the pictures I took. I didn't realize the allen key adjustment was at the bottom of the stud. I'm still not sure about the lack of seal with the bracket between the primary & nut. However, this should put my mind at ease regarding my primary chain.
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  #9  
Old 5th October 2009
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Default Chain slack

Quote:
Originally Posted by MinnSporty View Post
You guys rock. Thanks for the suggestions! I am going to try putting the stud back to where it was in the pictures I took. I didn't realize the allen key adjustment was at the bottom of the stud. I'm still not sure about the lack of seal with the bracket between the primary & nut. However, this should put my mind at ease regarding my primary chain.
You can check the chain play through the little inspection cover further up on the side of the primary cover.
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  #10  
Old 5th October 2009
95 sporty 95 sporty is offline
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+1 on checking the chain through the inspection cover.Rotate the back wheel till you find the tightest spot on the chain and adjust with the allen to 3/8 -1/2 in. play.this is the specs on my 95 don't know about yours but it should be the same.
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