Question about 2007 Harley Davidson XL 883 Sportster

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04 Sportster 883 gearbox Clunk.

Does anyone know how I can stop my 2004, 883 sportsters gearbox from clunking when I change through the gears, it clunks changing up and also when changing down. Clunk, clunk, clunk ferkin' clunk everywhere I go...... Clutch appears to be working fine, no clutch drag at all, probably a case of when I put it into gear it frees the plates so no drag apparent. If I start the bike pull in the lever and put it into 1st gear to ride off it clunks, but if I start the bike pull in the clutch lever and wait for a moment...perhaps 5 seconds give it a blip on the throttle it'll just snick into gear the way I think it should, so it's as though the plates are not freeing up... but with there being no drag that doesn't appear to be the case. I use the Harley Davidson gearbox oil designed for the bike, I was thinking perhaps changing the oil which might stop the plates sticking (if that's the case, but I'd like to keep with the H.D. oil...) or dismantling the primary to have a look to see if there is problem with the plates, maybe a burred edge? surely not on a bike that age. Or is it a case of "They all do that" Oh God!! I bloody hate that saying.

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  • mike sweat Aug 19, 2013

    i have a simular problem with my dyna wide glide that by giving a little bump

  • mike sweat Aug 19, 2013

    on the throttle with the cluch ingaged you can avoid the clunk so far i dont think the trouble has been properly understood

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Pull the clutch lever in and out several times before droppin it into 1st its sort of get n use to it mental dirt bikes have the same set up

Posted on Sep 06, 2009

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Big Twins clunk too, especially into 1st with a cold motor, even if you free the clutch off first. When I remember, I snick it into gear, pull in the clutch and roll it back and forward to free off the plates. And it still clunks. Sometimes, you will slip from neutral into 1st, almost with no effort, and no clunk and so smooth you don't believe it's engaged (but it is). Weird. I have smooth changes from 4th to 5th and back again, sometimes from 3rd to 4th, but 3rd to second and second to 1st are always a BIG clunk, even if you give it some stick to try and match the revs before changing down. I now go from second to neutral and then into 1st, which is not a lot of fun when you are negotiating a hairpin on Glenquaich at the time... A tighter primary chain seems to reduce the clunk, and there are those who say that auto primary adjusters/tensioners (does a Sporty have one of them?) reduce the clunk. Some disagree... Assume you find it's much better when it's hot..

Posted on Nov 20, 2008

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SOURCE: 2000 Harley Davidson XLC Sportster 883 won't start

the heat from the bulb being continiuosly on may have melted a wire inside your headlight?

Posted on Jan 27, 2010

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2004 Harley Davidson XL 883 Sportster starter solenoid clicks


Hi, Dennis you turn on the ignition switch press the starter button and all you get is the dreaded "CLICK" or "CLUNK" now before testing any electrical component in the Starter System it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries. Depending on battery voltage starter relays and starter solenoids can make the same noise when you hit the starter button. You can easily determine which one is at fault by the following two simple tests:
STARTER RELAY- place your thumb and index finger on the starter relay and press the starter button, if you feel the click then the relay is faulty and needs to be replaced.
STARTER SOLENOID- bridge the positive and negative poles of the solenoid with a small screwdriver if you get a loud clunk then the solenoid needs to be rebuilt or replaced as necessary. If the engine turns over then replace the starter relay otherwise the usual suspects for a faulty starter solenoid are:
1. Battery terminals have loose or corroded connections.
2. Battery cables faulty due corroded or broken internal wiring at the cable connector especially the "NEGATIVE" cable which needs to be checked at "BOTH" ends.
3. Battery voltage, must be 12.5 volts or better, voltage from the battery to the main circuit breaker to the ignition switch to the security/ignition fuse to the TSM/TSSM module to the engine stop/run switch to the starter button to the starter relay to the green wire that connects to the starter solenoid must not drop more than 1/2 volt of battery voltage.
4. Disconnect spark plug cables, with a voltmeter connected to the battery, the ignition switch in the on position, the kill switch in the run position, the starter button depressed, starter engagement should not bring voltage below 9.6 volts DC. If the voltage is below 9.6 the battery is faulty and must be replaced. I "HIGHLY" recommend a maintenance free AGM battery typically they have more amperage for cranking.
5. Faulty starter relay, check continuity.
6. Faulty starter solenoid, check contact plate and shoes for excessive electrical erosion/etching, refurbish as necessary or invert contact plate and use the virgin backside. Check contact shoes for being loose. Replace solenoid if the negative function is still a final outcome.
7. Faulty starter, bench test starter with a 12-volt battery if negative function check, decontaminate and undercut armature commutator segments as necessary, check segments with an ohmmeter probe each one and the segment next to it for shorts. Have the armature tested with a growler and field coils, and brush plate with an ohm-meter for opens, shorts or grounds. Replace brushes if less than .438" It is generally cheaper to overhaul/refurbish a starter motor than buying a new one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a wonderful day.
Won start clicking noise The Sportster and Buell Motorcycle Forum The...
2004 Harley Sportster Service manual pdf
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2005 Harley Davidson Sportster 883 Owner Manual
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Jun 17, 2018 | 2004 Harley Davidson XL 883 Sportster

1 Answer

2005 sportster 883 stopped at light,bike in 1st gear, now will not come out of gear and have play in shift lever


when you stop at a light you need to reve the throttle to get it in to nuteral the gears in the ****** are not lined up you should sift it first before you stop.

Aug 28, 2011 | 2004 Harley Davidson XL 883 Sportster

1 Answer

My Harley 883 Sportster suddenly became stuck in 5th gear.


More than likely the shifter pawl has broken. Breaking in 5th gear is kind of unusual however, they usually break between first and second.

You'll have to remove the outer primary cover to look at the shifter pawl. It's partially covered by the clutch assembly.

Mar 07, 2010 | 1993 Harley Davidson XLH Sportster 883

1 Answer

When changing gear get a clunk when warmed up


Probably not, but possible. Sportys do clunk a bit when shifting gears. As long as it's not a huge bang, it should be OK. Using different trans/primary fluid may help. As for the whine, I would remove the primary chaincase cover and make sure your primary chain is adjusted properly. 5/8 to 7/8 slack at the tightest sopt. Adjust the clutch as per service manual instructions too. Dragging clutch will make for a hard shift. Check ALL nuts and bolts for tightness and look for bent parts. There is a VERY remote possibilty that when you went down and the shifter hit the ground you bent a shift fork, but like I said it's a remote possibility.

Jul 10, 2009 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

2004 drag pipes on 2001 883 sportster


probaly not,up to 2003 will work,2004 was a model change

Jul 04, 2009 | 1993 Harley Davidson XLH Sportster 883

1 Answer

Motorcycle transmission


There is a spring inside the Primary that pulls the shifter back to the neutral position....it is broken......common problem with the Sportster.

May 19, 2009 | 2004 Harley Davidson XL 883 Sportster

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