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Sometimes, constant mesh transmissions can be "problematic" if they're shifted at the wrong RPM. Usually when the road speed and the particular gear at idle can cause the gear dogs to "collide" instead of "fit." This can cause hard shifting, bent forks and false neutrals.
I ended up just taking it to the dealership. The bike is still under warranty even though I had to sign a paper that said because I modified the exhaust an tune it could void the warranty. I'll let you guys know how it turns out
Two service technicians at the dealership took the bike out and nobody could replicate the issue. I don't see how that's possible but I'm back to square one
last update just in case this helps someone else in the future -
The lead tech was able to reproduce it. He said that you once you downshift, you have to take your entire foot off the shifter and let it return.
I can't let the ball of my foot touch the shifter after it's clunked into gear on the downshift. Said it's totally fine to do that on other bikes, his Softail included but for whatever reason you can't do it on my bike and that's just how it is
This happens to me sometimes, and I've noticed it on all 3 Harley's I've owned. I used to race motorcross and I would use the shifter as a footpeg sometimes, lots of times. I think it's just me and my instincts trying to ride it like a dirt bike sometimes and it happens. Always able to recover by finagling the clutch lever, shifter peg, in certain combos to get it back. Never caused an issue.
Well I figured it out. Got the bike home and took the shifter off. there is a plastic spacer between the shifter and the outer primary cover. That plastic spacer was warped and causing the shifter to bind when it would return on downshifts.
Went to the dealership and got a new one for $2. Put everything back together and the problem is solved.
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