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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 30th January 2008
slavcha slavcha is offline
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Default 2002 883c stuck in fifth after a fall

I let my brother ride my bike with about 3k miles on it. He was a bit underexperienced on the sportster, didn't make it into a corner and dropped the bike on it's left side. The belt was cut (probably cut by a stone). After I got the bike back to my parents house in SC I just took a few pictures, put a new belt on it, but couldn't change any gears. So my question is what do I need to get into the gear case? Any special tools Anything that I should be aware of I don't have a manual yet and will try to find one before I get into it. If anyone has a link with instructions and preferably pictures that would be helpful. Here are some pictures of the damage.

Thanks for your help. Chester.
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  #2  
Old 30th January 2008
slavcha slavcha is offline
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I cant post any pictures just yet
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  #3  
Old 30th January 2008
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Here is a link to one of the pictures of the damage
http://img147.imageshack.us/img147/1...c01141sxi3.jpg

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  #4  
Old 30th January 2008
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At least your model still has a trap door to get to the tranny. After '03 you have to pull the whole motor and split it in half to even get to the tranny. That's one thing that pissed me off to no end for not knowing they changed that before i bought my '05 model. That was one of the cool things that seperataded h-d from the Japanese bikes. I guess another example of planned obsoletion, like when the cost of repairs out weigh what its worth.
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  #5  
Old 30th January 2008
ScreamingEag1e ScreamingEag1e is offline
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Quote:
Originally Posted by slavcha View Post
I let my brother ride my bike with about 3k miles on it. He was a bit underexperienced on the sportster, didn't make it into a corner and dropped the bike on it's left side. The belt was cut (probably cut by a stone). After I got the bike back to my parents house in SC I just took a few pictures, put a new belt on it, but couldn't change any gears. So my question is what do I need to get into the gear case? Any special tools Anything that I should be aware of I don't have a manual yet and will try to find one before I get into it. If anyone has a link with instructions and preferably pictures that would be helpful. Here are some pictures of the damage.

Thanks for your help. Chester.
I can't see the pic here at work, but I had the same issue (1st gear) with no visible damage (except for some small scrapes on the shift lever). The resolution was to replace the "Gear Selector Shaft". The force of impact jammed it and damaged the end causing it to not be able to engage the gears. So, you might want to check this first.
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  #6  
Old 30th January 2008
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Question

Quote:
Originally Posted by slavcha View Post
I let my brother ride my bike with about 3k miles on it. He was a bit underexperienced on the sportster, didn't make it into a corner and dropped the bike on it's left side. The belt was cut (probably cut by a stone). After I got the bike back to my parents house in SC I just took a few pictures, put a new belt on it, but couldn't change any gears. So my question is what do I need to get into the gear case? Any special tools Anything that I should be aware of I don't have a manual yet and will try to find one before I get into it. If anyone has a link with instructions and preferably pictures that would be helpful. Here are some pictures of the damage.

Thanks for your help. Chester.
You stated your bike was dropped on the LEFT side and that the belt was cut, most likely by a stone. I have no idea other than what others have said, but a I have a 2002 XL883C and my belt is on the RIGHT side of the bike.
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  #7  
Old 30th January 2008
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Check first to see if the shifter is bent or otherwise hanging up on something. Try loosening it to make sure it's not dragging on the cases.

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  #8  
Old 30th January 2008
slavcha slavcha is offline
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Check first to see if the shifter is bent or otherwise hanging up on something.
Yes shifter was bent, ill try to post pics later.
You stated your bike was dropped on the LEFT side and that the belt was cut, most likely by a stone. I have no idea other than what others have said, but a I have a 2002 XL883C and my belt is on the RIGHT side of the bike.
sendpm.gif
Yes he dropped on left, and piked-up a stone while sliding?
I didn't see it happen, i will post more pics later tonight.
Thank you all for your replys
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  #9  
Old 30th January 2008
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Shu Shu is offline
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slavcha,

Start simple. These trans are tough and I doubt anything serious has occured from it being dropped. You need to realize that the transmission will not shift from 5th to 4th to 3rd etc unless the bike is rolled around a little bit to line everything up between shifts. First things first though before you try to force it into any gears. Remove the derby cover and inspect that when you pull the clutch lever that the cable is working and opening the clutch pack. Make sure everything in there is in order and there are no broken peices (which I highly doubt other than maybe the clutch cable). Then get the shift lever straight enough so it'll move freely up and down through the gears. If these look good, put it on a jack so that the back wheel is off the ground and while turning the back wheel down shift the transmission. If it is still stuck in gear try upshifting to make sure it is not stuck between gears. If nothing gets it freed up, maybe fire it up and try it with the engine running. If it still is stuck, then you have something deeper in the transmission out of line and you will need to get in there. If that is the case, wait for the service manual.
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  #10  
Old 30th January 2008
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cootertwo cootertwo is offline
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VERY SIMPLE solution..... You take your brother's head, and bang it hard, against the shift lever, until it comes out of fifth gear, or until his brains come out his ear, which ever one happens first.
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