Sportster tranny problems...

Hey all...I have a problem that I'm hoping that ya'll can help me with.

My brother-in-law has an old Sportster (1993 883 Hugger with 1200 bore kit). It has a shifting problem which over time progressed from an annoyance to being stuck in gear now.
With the primary cover off I can shift through the gears. After putting the cover on it no longer shifts. The mechanics at Thunderbird couldn't figure out the problem but they were also the ones who broke the clutch hub. The bike has a new Baker five speed transmission, new clutch hub, new Barnett extra plate clutch pack, and new shift mechanism. Roughly two years ago we put in a new stator and voltage regulator in. Also has new Vance and Hines pipes. The engine is in good shape and starts easily. Please help!!! I'm trying to get him back on the road. Thanks, Mike

If it will shift with the primary cover off then it stands to reason thet there is an alignment issue with the shifter shaft. Even so, this is highly unlikely the root cause.
Without looking at it with my hands I am sorry I can't be of much more help.
Hopefully someone else here has experienced this problem and can help you better....

[Wrightturn]

Hey medicmike,
Never seen a seal so tight it would interfere with shifting. Warped primary cover ? Did the dealer put the clutch hub on with an air wrench ? Retrace the "repairs" to the last time it was working. Did they use the correct shift drum for the Baker trans ? Broken shift fork?
Be glad you don`t have a 2004 or newer bike. You have a trap door and can pull the trans without pulling the engine and spliting the cases. Let us know what you find.