Go Back   Harley Davidson Forums > Harley Davidson Motorcycles > Sportster Models
Sign in using an external account
Register Forgot Password?
Search

Sportster Models 883, 883 Custom, 1200 Custom, 883L, 1200L, 1200S, 1200 Roadster, XR1200, and the Nightster.
Sponsored by: Rush Racing Products

Reply
 
 
 
P
 
Thread Tools Search this Thread
  #1  
Old 10-27-2010, 10:15 AM
vulcho vulcho is offline
Hang Around
Join Date: Jun 2010
Posts: 8
Default Removing Shifter Shaft on '09 Sportster

I need to remove and replace the shifter shaft on an '09 Sportster Iron.

Searched forums but couldn't find anything on instructions. Mechanic says about 2 hours for the job so I figure it can't be that hard to do myself.

Any guidelines on how to accomplish this? Any special tools necessary?

Thanks.
Reply With Quote
  #2  
Old 10-27-2010, 01:07 PM
kahaone kahaone is offline
Road Master
Join Date: Nov 2007
Location: Berwick, Pa
Posts: 1,083
Default

Quote:
Originally Posted by vulcho View Post
I need to remove and replace the shifter shaft on an '09 Sportster Iron.

Searched forums but couldn't find anything on instructions. Mechanic says about 2 hours for the job so I figure it can't be that hard to do myself.

Any guidelines on how to accomplish this? Any special tools necessary?

Thanks.
When you say "shifter shaft" are you referring to the part that goes into the tranny? Or the shifter pedal?
I figure you do mean the pedal, and not the shaft that goes into the tranny, since that shouldn't be a problem on an '09 bike.
If you are just putting on a new shifter pedal, that is simple and you should be able to figure it out yourself just by looking at it for a minute. It shouldn't take a rookie anymore than 30-45 minutes to change a shift pedal.
If it is the shaft, you need to get a manual to do that if you want to try it yourself with no previous knowledge of the part.
__________________

2007 Sportster with.....some stuff.
Reply With Quote
  #3  
Old 10-27-2010, 01:28 PM
vulcho vulcho is offline
Hang Around
Join Date: Jun 2010
Posts: 8
Default

I am referring to the splined shaft going into the transmission -- not the shifter arm or peg. I'm looking into the manuals on eBay but wanted to see if anyone's removed the shifter shaft so I can get some instructions, pointers, and things to look out for.
Reply With Quote
  #4  
Old 10-27-2010, 01:38 PM
kahaone kahaone is offline
Road Master
Join Date: Nov 2007
Location: Berwick, Pa
Posts: 1,083
Default

Quote:
Originally Posted by vulcho View Post
I am referring to the splined shaft going into the transmission -- not the shifter arm or peg. I'm looking into the manuals on eBay but wanted to see if anyone's removed the shifter shaft so I can get some instructions, pointers, and things to look out for.
I haven't done that, so can't help right now. If no answers by late tonight when I get home from work, I'll look in my manual to get you an idea.

What happened to yours that it needs replaced already???
__________________

2007 Sportster with.....some stuff.
Reply With Quote
  #5  
Old 10-27-2010, 03:02 PM
vulcho vulcho is offline
Hang Around
Join Date: Jun 2010
Posts: 8
Default

Layed it down. Wet road, dark morning, and driver ahead slammed brakes approaching intersection - not sure why. Minor scrapes on body and bike. Everything is an easy fix except for shifter shaft. Lucky in every respect.

I've never taken the primary cover off so I'm not sure what's involved. (i.e. Do I need to lift the bike? Drain pan? Refill a fluid? Special tools? Extra components needed in replacing shaft (gaskets, washers, etc.)? Just general info like that. I'm no mechanic but I figured out how to replace my car's CV joint on my own so I don't imagine it being that hard to do this.
Reply With Quote
  #6  
Old 10-27-2010, 05:40 PM
WRAITH's Avatar
WRAITH WRAITH is offline
Road Warrior
Join Date: Sep 2006
Location: Mission,BC.Canada
Posts: 1,278
Default

Shifter shaft removal looks easy, no special tools required, just a torque wrench. You will need a new primary cover gasket, derby cover gasket and the shifter shaft seals. A service manual will help a lot. Drain the primary/transmission while the bike is on the side stand. You should get a quart(1 liter) of oil out. You can replace it with Harley gear lube or NON-synthetic 20w50 motor oil. If you don't have a bike lift, you could lean the bike against a wall. Wrap a bungy cord or rope around the brake lever to prevent the bike from rolling. Follow the procedures in the service manual, it should take you less then 3hrs. to complete.
__________________
2006 XL1200c. Stage 1, Chain drive(say no to rubber bands). I am a Rider, not just an owner.
Reply With Quote
  #7  
Old 10-27-2010, 07:09 PM
vulcho vulcho is offline
Hang Around
Join Date: Jun 2010
Posts: 8
Default

Thanks. I just got the manual off eBay so I'll probably tackle it in the near future.

Appreciate all the help.
Reply With Quote
  #8  
Old 10-27-2010, 07:57 PM
Gpsjr10's Avatar
Gpsjr10 Gpsjr10 is offline
Outstanding HDF Member
Join Date: Jun 2007
Location: Elyria, OH
Posts: 2,533
Default

I dropped mine 1 week after I got it. Bent the shaft enough to make the shifter arm rub against the primary cover. I just removed the shifter arm and (carefully) bent it back straight with a piece of 1/2 in. pipe. Then put the shifter arm back on. No problems, no seal leaks.
Reply With Quote
  #9  
Old 10-27-2010, 09:38 PM
vulcho vulcho is offline
Hang Around
Join Date: Jun 2010
Posts: 8
Default

Going on a similar train of thought, another alternative I just discovered is that I only need to pull the shifter arm about 1/16" to 1/8" OUTBD to get more than ample clearance so the arm doesn't hit the primary cover (on FWD side by the peg). Then tighten the Allen head fastener and you're all set.

If you need to move it out more than that, or don't want to move it out at all, you can:

Get the new shifter arm, and carefully bend it away from the bike on a vice ensuring the bend is as uniform as possible and somewhere near the middle of the arm -- i.e. away from the fastener holes. Again, you're bending the shifter arm, not the part that goes into the transmission. And you're doing this with the arm OFF the bike and onto a vice. That way you are not applying pressure on the transmission; and I doubt it would look aesthetically bad if you only bend the arm 1/8". Then install the arm into the bent shaft, and finally install the shifter peg.

Of course, no way to know if any damage was caused to the transmission during the fall and ideally the best option would be to replace the bent shifter shaft and inspect the transmission when the primary is pulled. But at least it's a simple and cheap alternative that can get the bike moving.

Hope this helps any other folks out there.

Last edited by vulcho; 10-27-2010 at 09:41 PM..
Reply With Quote
  #10  
Old 10-28-2010, 12:13 AM
woodworking1's Avatar
woodworking1 woodworking1 is offline
Road Master
Join Date: Jul 2007
Location: Maryland
Posts: 765
Default

[QUOTE=vulcho;
Of course, no way to know if any damage was caused to the transmission during the fall and ideally the best option would be to replace the bent shifter shaft and inspect the transmission when the primary is pulled. But at least it's a simple and cheap alternative that can get the bike moving.
Hope this helps any other folks out there.[/QUOTE]

You cant inspect the transmission through the primary on a 09, You have to crack the case. No way would I run a bent shaft or even try bending it back! No telling what damage you can do to your tranny running like that. I would pull the primary cover and replace it! Just my .02.
__________________
1999 883/1200 custom
SE stage 1 A/C, drag pipes,
Twin Tec ignition
Foot Clutch, Custom shifter
16" apes, Headlight lift,
etc., etc., etc.
Reply With Quote
Old 10-28-2010, 12:13 AM
 
 
 
P
Reply

Similar Threads
Thread Thread Starter Forum Replies Last Post
Heal Shift Removal.. Hacksawed Shifter Shaft.. jasnusc Touring Models 74 10-16-2013 05:32 AM
6 speed shifter shaft bushing GNrider Primary/Transmission/Driveline/Clutch 0 09-11-2013 11:52 PM
Questions: Bagger Toe/Heel Shifter Arm Removal Skippy97 Touring Models 31 09-21-2012 01:02 PM
Problem removing forward shifter WhiskeySierra Sportster Models 8 02-03-2012 12:33 PM
shifter fork shaft retainer clip jofixer Sportster Models 3 11-30-2011 12:14 AM


Tags
09, 2007, 2010, 883, arm, davidson, harley, installing, nightster, removal, remove, replace, rod, shaft, shift, shifter, sportster


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump

Join HDForums

Advertising
Featured Sponsors
Vendor Directory
Sponsors

All times are GMT -5. The time now is 04:54 AM.


Internet Brands, Inc.