Awe, Hell.....
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Road Warrior
Joined: Dec 2005
Posts: 1,643
Likes: 425
From: Mount Rainier, Washington
The big thing with a pawl spring breaking is whether or not it went through the gears. I had one fail coming off the freeway while I was downshifting. Same as you, same noise, and a floppy shift lever. Here's mine . . . (If you see multiple bits of spring, like below, or bits that look chewed up, that means the spring bits hit the gears. You have to check every tooth of every gear to be sure.) 
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Road Warrior
Joined: Dec 2005
Posts: 1,643
Likes: 425
From: Mount Rainier, Washington
actually I put my other bike up for sale when I thought I did major damage. It it sold, I was going to buy a Baker 6 in a 5
Dirt don't hurt
Joined: Jan 2011
Posts: 21,059
Likes: 4,534
From: Haslet Texas
FWIW Baker recommends the DD6 for the 80" EVO.
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Road Warrior
Joined: Dec 2005
Posts: 1,643
Likes: 425
From: Mount Rainier, Washington
Just to update this thread, I had a broken shift pawl spring and a damaged countershaft gear. Following Spanners advice, I was able to completely disassemble the trans up to the main shaft without removing the primary or starter. Although, the time spent trying to get that little shift shaft circlip off and back on again, I probably could have removed and reinstalled the primary a couple of times. I installed a Baker anti over shift pawl that has a better designed spring and I found a NOS Harley countershaft gear on Ebay for $20.00. I just need to finish torquing the external bolts down, add fluid and replace the oil tank and exhaust. Thank goodness there was no real damage.
I installed a Baker anti over shift pawl that has a better designed spring and I found a NOS Harley countershaft gear on Ebay for $20.00. I just need to finish torquing the external bolts down, add fluid and replace the oil tank and exhaust. Thank goodness there was no real damage.
