Question about Harley Davidson Motorcycles
Worn thrust bearing and shafts. Strip the gear box, fit new thrust bearing shims and selector arm. Adjust as required. Reassemble and top up with fresh oil.
Posted on Oct 25, 2013
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Posted on Jan 02, 2017
SOURCE: stiff shifting into second gear
Yes, too much slack can cause the problem. Remove the slack by adjusting the cable at both ends if needed. Here's the deal, if the clutch does not work fully, the engine is still applying pressure to the driven gear. The pressure on the gear does not let the shifter move freely.
Try this little test > on a clear road shift from 2nd to 3rd using the clutch but don't let off the gas when you shift. If the motor reved up when you shifted then the clutch was doing its' part at least a bit. Now do the same process but this time do not use the clutch at all. Instead, let off the gas when you shift. Letting off the gas lessens the drive pressure on the gears and will allow the shifter to better do its' part. Not using the clutch is commonly referred to a "power shifting ". If out on the road and the clutch cable breaks, this is a way to keep going for a bit.
As to worn dogs and shift forks, your bike is pretty new so I doubt wear is a problem. A bent shift fork is a possibility but since you have a funky clutch cable I suggest we keep it simple and start there.
Posted on Mar 17, 2009
Happens all the time, you shifter pawl return spring is broken. If you will put the transmission in neutral and lift or push down on the shift lever, you'll notice that the lever doesn't want to return to the "center position" on it's own. This is because the spring that brings the shifter back to the "center position" after a gear shift is broken. It is also not advisable to ride the bike until this is repaired. The broken end of the spring has been known to get caught up in the gears and actually bust the transmission cases in addition to damaging those gears.
This is not a simple repair job in the fact that all the "guts" have to come out of the transmission. The shifter pawl shaft will not come out of the transmission case with the gears on their shafts left inside the case.
If you want more detail, drop me a line at firstname.lastname@example.org
Posted on Oct 26, 2009
SOURCE: The bike is a 2006
It sounds like a broken shifter pawl spring. This part is inside the transmission and requires a teardown of the transmission. Not a simple job. Harley was having problems with them in the 5- speed transmission back in the '90's but I thought they had gotten that problem solved. There never was a recall as far as I know but I have replaced quite a few shifter pawl shafts. The spring is what returns the shifter back to it's "center" position between shifts. With the transmission in neutral, engine off, use your hand to gently push the shifter down to just before it shifts the transmission. Then let go of the shifter and see if returns back to the "center" position. Make sure the shifter or the shifter rod is not binding in any manner. If it will not return to center, I think this is your problem.
Posted on May 17, 2011
Tips for a great answer:
1-2 Shift Solenoid Valve
3-4 Shift Valve Bore Plug
Burned, slipping, missing
4th Servo Cover
4th Servo Pin
4th Servo Piston
4th Servo Seals
Rolled, cut or damaged
Slipping or No Fourth Gear
Slipping or No Fourth Gear Checks
DEFINITION: A large engine RPM increase is noted in fourth gear, Drive range, with little or no vehicle forward speed increase. First, second, and third gear operation are normal. Shifts into fourth gear are soft or do not occur. Fourth gear ratio is 0.705:1.
Automatic Transmission Fluid Level
Low fluid level
Transmission Main Line Pressure
Low transmission main line pressure
Oil Filter Assembly
• The oil filter assembly (100) is missing, plugged, or damaged.
• The oil filter seal assembly (101) is missing or is damaged.
Control Valve Body Assembly
• The 3-4 shift valve (362) or the 4-3 manual downshift valve (360) is stuck or binding.
• Debris is found in the passages of the control valve body (301) or of the control valve body spacer plate and gasket assembly (396)
Case Cover Assembly
Distortion or damage occurs at the manual valve (404) or at the case cover (401), causing PRN oil leak.
Driven Sprocket Support Assembly
A plugged third clutch oil passage in the driven sprocket support assembly (609)
Fourth Clutch Assembly
• The clutch plates (500-502) are worn, damaged, or misassembled.
• A missing or not seated fourth clutch spring retaining ring (601)
• A damaged spring assembly (602) or piston (603)
• Worn or damaged fourth clutch piston seals (604, 605)
Third Clutch Sprag Assembly
• The sprag (720) was misassembled or backwards on the inner race (661).
• A damaged third clutch sprag assembly (653, 661, 719-721)
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Trouble Code Conditions:
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Trouble Code Conditions:
Vehicle driven any forward Gear, and the TCM detected the ratio of the Input speed to the Output Speed did not match the current Gear Ratio (this test can take up to 5 minutes).
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