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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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

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May 02, 2010 | 2007 Harley Davidson XL 883 Sportster

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

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When changing gear get a clunk when warmed up

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Motorcycle transmission

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

May 19, 2009 | 2004 Harley Davidson XL 883 Sportster

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