The kid and I opened up the side of his 2001 1200 sportster, it wouldn't shift. After removing the clutch basket, we found the problem. The retainer clip that holds the ratchet cover on the shifter fork shaft, was gone. We are having a new one shipped and ratchet cover shipped. My question is: is this gonna happen again? It doesn't look like a solid design to me. Maybe someone has seen an improved way to hold that ratchet cover on the shaft. I was thinking maybe drilling and tapping a flathead 4mm screw into the cover with a hardened clip of my design. I also am aware of the clearance needed for the back of the clutch basket. any .02 will be appreciated as I don't know everything. Thanks.....

 

Never heard of that before. Strongly suggest you go to xlforum.net and ask there. Lots of very knowledgable folks on that forum. You'll get solid advice there for all things Sporty,

 

Most likely just a fluke. I would suspect that you will have no problems with the new unit.

 

I have seen the clip broken /gone before ..
my guess it was from a side impact to the shifter.
(imagine that ..lol) )
replace it , its good to go