Shifter failure

[Whopper]

Just when the weather turns good my Sporty has decided to missbehave. A 2002 XL1200, it began giving me shifting problems yesterday afternoon. Symptoms: When shifting from first to second gear the first attempt seems to find neutral, though the neutral indicator light doesn't come on. It may take one or as many as three more attempts before it catches second. It will then shift normally through the gears up to fifth. The down shift is also normal until attempting to downshift into second. Repeatedly pushing down on the shifter eventually will find second or first. When stopped I can find first by repeatedly pressing down on the shifter. The neutral indicator light might flicker when trying to find neutral but that's all.

When in second the bike performs normally so it doesn't feel like a gear problem but more like the gear selector has failed. Never having been inside the transmission I'm wondering if anyone has any clues as to what to look for or any tips.

[Buzz Kanter]

The first (and easiest) thing I'd is the clutch to make sure it is not too tight or too loose at the cable.

[unclepsycho]

When was the last tranny oil changed?
Both my bikes shift wierd after a lot of miles, then I change the oil and they seem to shift just fine. on my Baker 6-Speed, it seems to find nuetral between 4th and 5th ??? thats wierd.... after oil change it has no problem.
I have never been inside a trranny either (yet) , so I bet Frisco or Ace has(or a number of you all out ther) and can offer something a little more.

[frisco-rigid]

Hey Whop

Unc----I wish I could assist Whop but I'm not familiar with Sportster Trannys.. Bolo on Wrightturn & Ace..
My only advice would be to Make sure the shift linkage, cable, everything assoc. with shifting is adjusted perfectly..

My other comment is that it is Not really Neutral when you get a "neutral" between gears, other than the Real neutral of course,, it is only an in-complete shift and will eventualy jump into the intended gear just when you don't expect it.. Not good..

[Whopper]

Thanks Unc, Frisco. Last oil change was 3,000 miles ago and due now. I'll try that and adjusting the clutch and shift pawl. Looking at the parts manual it looks like an indexing mechanism rotating a drum that slides shift dogs back and forth. It just looks like a ton of work if I have to get the drum out. Snow flurries (in Alabama!!!) tonight so I'll stay in and start messin' with it.

[unclepsycho]

Glad you got a direction to look! and thats about the only good thing about snow... it can keep you indoors fixing stuff that needs it.

Thanks Frisco, I figgered it was hung up between gears, but never got a grinding sound. One time it did jump into gear like you mentioned...

[aceharleywrench]

I would suspect the shift pawl is out of adjustment.If you have the H-D service manual the adjustment procedure is straight forward & fairly simple,but you will need a #32 drill bit (most people don't have number drills in their home collection) Good luck & let us know if it works.

[Whopper]

Well, I'm back on the road. She shifts smoothly and all is right with the world. At one point I thought...no, I knew, I was in over my head. Pulled the drain plug and found metal filings clinging to the magnet about the size of a pencil eraser. Not having much experience with this trans I'm not sure if that is bad or normal.

Pulled the side cover off and couldn't see anything amiss. But, I was determined to find the problem so I coughed up $75 for a clutch puller and got the primary chain and clutch out of the way. The detent plate was loose and bent up and the retainer was missing - later found in pieces in the bottom of the trans case. Cover gasket and seal = $20, trans oil = $9, detent plate and retainer = $4. Yup, a 25 cent part caused a $4 part to fail and cost me over $100 and busted knuckles.

I followed the manual instructions for adjusting the clutch when I got her back together but the result didn't seem to fully disengage the clutch. After a few attempts I gave up and turned the adjusting screw and cable adjustment until I got the 1/16" to 1/8" free play at the lever and no drag on the clutch. A test ride showed no clutch slippage and easy shifts so I think I've got it right. Wish I knew what I was doing wrong trying to follow the book

Of course we now have 5 days of rain scheduled for 'Bama but at least the bike is no longer scattered accross the garage floor.

[JCourneyaP]

Good deal Whopper. Busted knuckles come with the job. Hey if you find something wrong in the manual send a note off to the MOCO to update.

Now get it out on the road and ride the hell out of it to make up for lost time.

[frisco-rigid]

Yeah baby

Whopper gets the "I'm not giving up just cuz I'm over my head" Gold Star..!!

Now----That's NOT over your head anymore,, cool huh..