Question about Harley Davidson XL Sportster 883 Motorcycles

1 Answer

Needing a service manual for 2004 883 xl. money is tight and I need to split cases to repair shift assembly and shifiting forks

Posted by on

1 Answer

  • Level 3:

    An expert who has achieved level 3 by getting 1000 points


    An expert that got 10 achievements.


    An expert that got 5 achievements.

    Brigadier General:

    An expert that has over 10,000 points.

  • Master
  • 4,565 Answers

On your Sportster, you don't have to split the cases to repair the shift assembly or the shifter forks. All you have to do it remove the primary drive, (primary chain, engine sprocket, and clutch assembly) and the front belt pulley from the other side.

Then, there are four bolts that hold the access door of the transmission behind the clutch assembly. Remove these bolts and pry the door and both shafts of the transmission out.

I've never seen a problem with the shifting forks in ANY Harley transmission. I may have just been lucky but whenever I worked on transmission shifitng problems, it was always something else. Why do you think you need to pull the transmission. Odds are, your problem is in the shifter pawl. These are notorious for giving problems. Unless of course, you blew second gear trying to speed shift it.

Good Luck

Posted on Sep 09, 2010

1 Suggested Answer

  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

a 6ya expert can help you resolve that issue over the phone in a minute or two.
best thing about this new service is that you are never placed on hold and get to talk to real repairmen in the US.
the service is completely free and covers almost anything you can think of (from cars to computers, handyman, and even drones).
click here to download the app (for users in the US for now) and get all the help you need.

Posted on Jan 02, 2017

Add Your Answer

Uploading: 0%


Complete. Click "Add" to insert your video. Add



Related Questions:

1 Answer

What causes the shifter to shift ******* a 91 CBR 600 f2

Weak Transmission "bent shifting Fork" shifts on it's own due to The Bent fork and Engine Vibration,,"DANGEROUS" Repair Immediately,,"Split the Cases to the Transmission sorry I wish it wasn't

Sep 23, 2015 | Motorcycles

1 Answer

Do you have to split the cases on 1996 zx6r ninja 600cc f2 to change the shift forks

Dude shift you dont have to spilt ****** can go threw oil pan just difficult since you are working under the bike....haynes manual will explain it all,,,im having same problem mine wont shift down and no cant get gotta find a good place on the web to buy chaep good parts!

Jul 04, 2012 | 1996 kawasaki ZX-6R Ninja

1 Answer

How do i change the shifting forks on a 97 1100sabre

I really hate to rain on the parade, but you are talking about tackling a project that many shop mechanics don't relish doing. The engine has to come out of the frame. Then the entire top end gets torn apart; exhaust pipes, cylinder head, OHC chain, cam, cylinder and piston. Now do the same disassembly for the rear cylinder. Next, the right side case and left side case covers get removed and everything inside the case covers must come off. That means the clutch, the shift shaft assembly, the starter and related starter assembly, crankshaft drive gear, oil pump, intermediate drive gears, water pump, all engine electrics, rotor and drive sprocket. Now you are ready to separate the center case halves. This will allow you to get to the shift forks to install new ones. You will need some special tools; impact driver, case splitter, rotor puller, torque wrench and a factory service manual. The standard set of metric wrenches and sockets plus screw drivers, circlip pliers, hammer, etc... will also be needed. Don't even think about doing the job without a service manual. Oh, by the way, did I mention that you must next put it all back together and time the cam shafts as well? The bottom line is that it will cost you more for the dealer to put together the three or four boxes of parts you take to them than it would cost to just take them the entire bike and then say "fix it". I DO NOT RECOMMEND THE HOME MECHANIC TRYING THIS REPAIR. If I have scared you about doing the repair then I have done you a BIG favor. Respectfully, Tombones49. Please rate my answer. Thanks.

Jun 06, 2011 | 1998 Honda VT 1100 C2 Shadow Sabre

1 Answer

The shift arm broke and is just dangling and does not go in gear?

There is a part that is called the shifting fork. It is a pain to change. Where the shifter attaches to the shifting fork there are teeth on the shifter and the shifting fork. The shifter has a bolt through it to tighten the shifter. I would try taking the shifter off and cleaning both the shifting fork, which sticks out of the side of the motor, had teeth or knurl then a div-et then knurl. Clean it and the shifter up really good and reinstall the shifter. Tighten the bolt on the shifter really tight. If this don't fix it, then you can tack weld the shifter back on. But if you do this do it on the outside of the shifter where it can be ground back off, in case you ever have to split the case. The shifting fork goes all the way through the motor to the other side. 

Sep 04, 2010 | 1991 Suzuki DR 350 S

1 Answer

Yamaha SR1 25 will not go into second Gear

The bike has a bent shift fork. The top end comes off then the side cases, clutch, starter, rotor, stator, etc... Then the case halves get split and you have access to the shift drum and forks. This is pretty major surgery on the engine and not reccomended for the novice mechanic. Some special tools are needed and if you don't have experience inside an engine, don't even think about doing the repair without a service manual. A dealer will probably charge $800 or so for the repair.

Jul 26, 2010 | 2001 Yamaha SR 125

2 Answers

My 2003 rm 125 transmission slips out of gear.

im having the same problem with my 2003 rm 125, tombones49 is wright about the shift forks.

May 27, 2010 | 2003 Suzuki RM 125

2 Answers

1979 Suzuki gs750 bent shift fork how to replace

To replace the shift fork or forks you will need to remove the engine from the frame and lower engine crankcase if you are not accustomed to doing a job like this take it to a motorcycle mechanic or at least get the tools you will need and a service manual.

May 04, 2010 | 1977 Suzuki GS 750

1 Answer

Cant shift down into first gear

If not bent too radically, the shift pedal can be bent outward and away from the frame. Be sure the 10mm lock bolt is tight on the shift shaft. If it still will not go into first gear, the bike has a bent shift fork. The case must be split to get to the fork. Somewhat expensive to repair. Be sure to install new crank bearings and seals.

Dec 16, 2009 | Yamaha YZ 125 Motorcycles

2 Answers

I need to know how to dis/reassemble a 1974 DT 360?

A service manual ( if you can find one ) is what you need. The second thing you need is repair parts. They are pretty hard to find. Babbitt's, a well known distributor, only has parts left in stock for the top end. Go to their website,
and you can see what is left. There's also a diagram of the crankcase center halves. If you can't get the repair parts, spending hours doing an engine teardown is fruitless.

The teardown will require a flywheel puller, a case splitter, an impact driver, and a torque wrench (somewhat optional). Disassemble the top end then remove the left and right side case covers. Remove the flywheel and related electrics, the clutch, crankshaft drive gear, oil pump, kick starter, shift shaft assembly, shift drum end cap and index pins. Now remove the screws on the center case and you can then split the case. This gives you access to replace shift forks, gears, and bearings. Note that crank seals can be replaced without splitting the case.

I am not trying to be a smart *** here, but re-assembly is just the reverse of dis-assembly. This is why a manual would help. Another potential source for parts is to Google motorcycle salvage yamaha .
The normal things you would need to replace inside the center case would be bent shift forks (if shifting is the problem), busted gears, crank bearings and seals, and sprocket shaft bearing and seal. All else can be replaced by removing just the side covers.

Dec 10, 2009 | 1974 Yamaha DT 360

2 Answers

My banshee wont shift past 2 gear

You have a bent shift fork. The repair means taking the engine out of the frame then removing the top end, removing the flywheel and electrics, removing the clutch , shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to remove the gears and crankshaft and then the shift drum and bent shift fork. Next you get to put it all back together. This is a pretty big job for the home mechanic.

You will need an impact driver, flywheel puller, case splitter and torque wrench plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it".
I normally tell people to take it to the shop just so they don't get into such an involved project.

Free service manual PDF download at >

Please rate this solution. Thanks!

Apr 19, 2009 | 2003 Yamaha YZ 250

Not finding what you are looking for?
Motorcycles Logo

Related Topics:

217 people viewed this question

Ask a Question

Usually answered in minutes!

Top Harley Davidson Experts

Arnie Burke
Arnie Burke

Level 3 Expert

4514 Answers

Gills Lango

Level 2 Expert

195 Answers


Level 3 Expert

4336 Answers

Are you a Harley Davidson Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides