Question about 2003 Harley Davidson XL 1200 C Sportster Custom

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Transmission shifter internal damage. Only 1st and 2nd gears available. At 25,000 miles is this a common problem and will the case have to be split for inspection and repair? No external damage visable. I have not been hard on the bike and am the original owner.

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  • tdebear Aug 07, 2009

    It was a broken torsion spring. Removed cover, replaced spring.
    Ted

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No it is not common and no they dont have to split the cases but the will have to disassemble the primary to access the transmission

Posted on Aug 06, 2009

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1 Answer

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Hi, Anonymous and the usual suspects are:
1. Clutch dragging slightly.
2. Primary chaincase overfilled with lubricant.
3. Corners wore off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. A loose shift lever on shifter shaft.
7. Shifter forks sprung.
8. Shifter pawl needs adjusting.
9. Heel/toe shifter coming in contact with the floorboard.
10. Transmission oil too heavy.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
http://www.starbikeforums.com/forums/15-stratoliner-roadliner/3901-transmission-issues-shifting-into-1st-gear.html
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http://atelierstarsclub.free.fr/pdf/roadliner-stratoliner-service-manual.pdf
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1 Answer

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Hi, Anonymous and the usual suspects are:
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1 Answer

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Hi, Mike and the usual suspects are:
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1 Answer

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Hi, Stephen_witn and the usual suspects are:
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1 Answer

No 1st,2nd,3rd,and reverse gear,but have 4th,5th and 6th gears


You don't say what year, make or model your Chevy is, so I can only give your a general answer.

I assume the you have a floor shift manual 6 speed transmission. The most likely problem is a broken shift actuator rod in the transmission.

The shift handle goes into the top of the transmission. On the end of shifter there is a ball or rounded end. The end goes into three or four slots on the top of the gear case. Each slot is connected to a rod that controls a particular set of gears. ie 1-2, 3-4, 5-6 and reverse is by itself. Moving the shifter left and right select which slot the shifter controls and the forward-back moment selects the gear.

On some model cars the top or the gear case can be accesses from inside the vehicle by removal of the rubber boot around the shifter. There is a small chance that the repair could be made without removal of the transmission. The problem could also be major if the internal gear (packs) or bearings are damaged. In either event, you will need the services of an experienced transmission mechanic.

I hope this helps, If you can leave a further question in the comment, perhaps I can give you more information. Good Luck.

J


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1 Answer

1992 FLSTF fatboy.. everything was ok when i started out onthe highway, 1st and 2nd gear seemed ok but when i shifted to 3rd gear , the shift lever got sloopy and would not go into 3rd gear or higher. 1st...


I hate to be the bearer of bad news but it sounds like the shifter pawl return spring has broken on the shifter pawl shaft. Harley has had a problem with these but there is not a recall notice on it as far as I know.

The fix is a major job in that all the primary has to be pulled as well as all the guts in the transmission. The shaft will not come out with the two shafts in the transmission. But, at least the five speed transmission is designed to do this with. Much easier than the older four speed.

I do not recommend that you even start the engine until this is repaired. I've heard of the broken spring getting into the gears and doing even more damage. I've been replacing them with either Sputhe or Jim's parts.

Good Luck
steve

Oct 02, 2010 | 1993 Harley Davidson FLSTF Fat boy

1 Answer

Transmission Problem or ????


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