Question about Maisto Harley Davidson Model Kit 1997 FLSTF Fat Boy

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Hi, 1997 evo , cannot get gears looks like the linkage is turning the sellector arm that goes into the box but all sloppy ! . don`t know how it happened left in shop to sell,, now this. Can you please tell me how it could of happened and is it an easy fix. Thanks Dave Hollands

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  • 4,565 Answers

This is a problem with all Big Twin Harleys. I've replace many of the shift levers and the shafts. To repair the job correctly, it's a big job. Since the lever is worn and gotten sloppy to the extent that it will no longer shift the gears, the shifter pawl shaft is probably worn to the point that it needs to be replaced as well.

To replace this shaft, the entire primary, both the outer and inner primary cover, will have to be removed. This includes the engine compensator sprocket, primary chain, and clutch assembly. The starter and the inner primary will have to come off. On the right side of the bike, the exhaust will have to come off so you can get the starter off. The "trapdoor" on the transmission will have to come off and the gear shafts removed to get the shifter pawl shaft out.

It's a major job. What causes it is the lever being made out of soft material and thousands of shifts made over the years. I guess someone could have abused the shift lever while it was sitting there but more than likely, it was badly worn to begin with. Sorry Dave. Like I said, this is a common problem.

Good Luck
Steve

Posted on Aug 21, 2010

  • 2 more comments 
  • bigdaddynite Jul 18, 2011

    Can you remove the shaft from the tranny, without remove in inner. On another forum it says that you can lower the inner case to from fault lever. Is there any short cuts you know of?

  • wd4ity
    wd4ity Jul 18, 2011

    No, every one I've replaced, I had to remove the trap door with both transmission shafts attached to the trap door. Do not take the nuts of the ends of the shafts, pry the trapdoor off it's dowel pins. Now, you don't have to remove the individual gears from the shafts like you do on the old four speed transmission either. You'll have to take the top off the transmission and remove the shifter cam and then remove the shifter forks and their shafts. Once this is out, it looks like you can slide the shifter pawl shaft out but it lacks about a quarter inch of coming free. I guess there may be some people that will slide the trapdoor and the two gear shafts back just far enough to replace the shifter pawl shaft, and then put them back in but if I'm going to pry the trapdoor off, I'm just going to take the whole thing out of my way. If you think there is another way, buy a service manual and see what they have to say. This job is complicated enough that I'd suggest that if you're going to do it yourself, I'd recommend a service manual anyway. There may be another way to do the job but this is the way I always did it. Go tohttp://www.bikebandit.com and have a look at what the transmission looks like on the inside. Remember, you don't have to take all the gears off the shafts, they all come out with the trapdoor.

    Good Luck
    Steve

  • bigdaddynite Jul 18, 2011

    Thanks I'll try that.

  • wd4ity
    wd4ity Jul 18, 2011

    You know the old saying. There's more than one way to skin a cat. Well, there may be an easier way to replace this shaft but I don't know of it. I can't figure out what the guys on the other forum are talking about "lowering a case". Once I got the transmission taken down this far, I cleaned the bottom of the case out while I was there. Also, all of the shifter pawl shafts that I replaced had broken the return spring. The piece of broken spring was lying in the bottom of the case. If this short piece of hardened spring metal were to get picked up by the gears, it will destroy the transmission, case and all. That's why I took everything out.

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