Question about 2003 Harley Davidson XL 1200 S Sportster Sport

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Sportster shifting problems pops out of first gear

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  • Harley Davidson Master
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Hi Anonymous, and the usual suspects are:
1. Shifter rod improperly adjusted.
2. Shifter drum improperly spaced or damaged.
3. Shifter engaging parts badly worn and rounded.
4. Shifter forks bent.
5. Damaged gears.
Good luck and have nice day.

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Posted on Jun 25, 2015

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Posted on Jan 02, 2017

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  • 4 Answers

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. :(

Posted on Sep 11, 2009

wd4ity
  • 4565 Answers

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

Posted on Aug 25, 2011

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Hi Sam, and the usual suspects are:
1. Shifter rod improperly adjusted.
2. Shifter drum improperly spaced or damaged.
3. Shifter engaging parts badly worn and rounded.
4. Shifter forks bent.
5. Damaged gears.
Good luck and have nice day.

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

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I have a 2004 harley davidson 883 sportster and it keeps popping out of 2nd gear the guy i bought it from said that he replaced the gear and it just needs to be broken in?


No, sorry to tell you that you don't need to break a gear in. There is something not quite right in the transmission if it's jumping out of gear. If I had to guess, he probably broke second gear speed shifting the bike, then replaced the gear and go the shimming messed up and it doesn't have the correct engagement with the shifter clutch dogs. To repair this, you'll have to pull the transmission out of the case. If your mechanically inclined, this isn't that difficult but you WILL need a factory service manual to check the transmission to find out what is wrong. Heck, he may have put the gear in backwards. Some of them will work that way but they'll jump out when power is applied or let off.

Good Luck
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Sep 11, 2010 | 2004 Harley Davidson XL 883 Sportster

1 Answer

My 02 Custom 1200 has developed a problem. When downshifting from 3rd to 2nd the action feels and sounds like the shift engaged only to find it is actually out of gear. Also, the neutral light goes right...


sounds like the shift drum in it that selects the gears is getting worn out or maybe the dog legs on the forks for the gears its self. my try changing the fuilds and flushing it out. to see if it helps.

Mar 10, 2010 | 2002 Harley Davidson XL 1200 C Sportster...

1 Answer

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. :(

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1 Answer

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Shifting paw or arm is broken in transmission. Very common! Or shifting fork is bent . Both due to hard shifting or abuse..........normally.

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