Question about 2005 Harley Davidson FLHRS - FLHRSI Road King Custom

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The shift lever on the transmission is loose, seems that the splines are worn as the bolt is tight

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Regrettably, this is a common problem on the five speed transmissions. Usually, not only is the shift lever worn, but the shifter pawl shaft is usually worn as well. To replace either is a major job. To replace the shift lever, the outer and inner primary must be removed. To remove the inner, the starter must be removed and the primary chain, compensator sprocket, and clutch assembly.

If the shifter pawl shaft is worn, the guts must be pulled out of the transmission. It looks like the shifter pawl will come out without doing this but it won't.

Repairing this problem correctly is a major job.

Posted on Sep 24, 2009

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You can remove the clamping bolt without removal of the either inner or outer primary case. Purchase a new clamp bolt from Harley (it comes with thread locker already on it). Install the new bolt and torque it to the correct value. This is very tight, but it must be done to provide the clamping force needed. If you have run with the lever loose for an extended time, you may have pounded the splines to a rounded shape and the lever/shaft must be replaced. Most of the time a simple change out of the clamping bolt is all that is required. Give it a try, it will only cost you a couple of bucks for the bolt. Clean the lever threads as best you can by using a can of brake cleaner with the long nozzle.

Posted on Mar 14, 2010

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f6f9381.jpgWorn splines on gear levers and shafts always result in loose levers or broken off bolts. When pinch gap has to be widened, (do not put any spacers between lever and shaft-it never works) the bolt entry angle must change or bolt will bind and snap before closing onto shaft. Turn the bolt into thread side to start of gap as protection for thread so you can elongate or drill larger diameter entry hole. ca1eb41.jpg

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1 Answer

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To check the adjustment of the shifter pawl, first you need to have that lever tight. Here's the problem. You probably are going to find that the lever will not tighten. The splines on the shaft are worn out. This is bad. You must pull everything on the left side of the bike to get to the lever to replace it. If the spines are worn on the shaft, even a new lever is not going to fix the problem, the shaft must be replaced. This is a major job as the guts of the transmission have to come out. The shifter pawl shaft is the one of the first parts put into the transmission and one of the last to come out.

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