Question about 2005 Harley Davidson FLHRS - FLHRSI Road King Custom
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
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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Posted on Jan 02, 2017
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