SOURCE: 1994 sportster xl shifting problem
Make sure your cltuch is disengaging. With the motor full hot (ride it a good while), shut iff the engine, put it in first, pull in the clutch and try to roll the bike. It should roll as easily (or almost as easily) as it would in nuetral. If it resist, loosen the clutch adjustment so it has plenty of free play in the lever. Ride and see if that makes a difference. If not, most likely you have a bent shift fork or shif shaft. :(
SOURCE: 2003 1200 sportster shifter wont shift stuck in
You may have a broken shifter pawl. It is located behind the clutch assembly in the primary. You'll have to remove the outer primary cover and the primary drive that includes the engine sprocket, primary chain, and clutch assembly. The shifter pawl is located behind the clutch. I would suggest that if you're going to fix the bike yourself that you purchase a service manual. In this particular case, there are a few settings that have to be made. It is difficult to explain how to make these adjustments using this form of communication. A picture is worth a thousand words in this case. Besides, if you repair the bike yourself, the money you save will more than pay for the book. Try this site for a manual. http://www.diyrepairmanuals.com/products.asp?cat=14286
Good Luck
Steve
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