1996 fxd 80ci 5spd
Hard downshift and hard to get into neutral.
Fluid needs change but level is good.
Is there any advice/direction you can give that will help in the correction process?


After receiving direction from loyal hdforum family members, I drained fluids, adjusted primary chain to within specs found in hd repair manual, adjusted clutch and lever to specs, refilled fluids to proper levels...
Took her for a spin and no change...once up to normal temperature, hard to downshift and hard to get into neutral.
(One note for the record is that during this process, I removed the primary cover so I could get a good look inside. I noticed that the teeth on the compensation sprocket are sharp on the tips.)

I then adjusted the primary chain tensioner down one more notch which still held chain free play within specs but right at the limit but did not recheck the clutch adjustment...figured that it should not have changed (please correct me if I am wrong about that)...now when I engage 1st gear the bike immediately starts to move forward.


I understand that air cooled engines run hotter and need bigger tolerances...and am wondering if an automatic primary adjuster like the one from Hayden Enterprises would be beneficial to solving this issue.

 

No, Control is everything, Springs do not give any control...

 

Sounds like a shifter pawl issue

 

Also sounds like you need a new compensator sprocket.

 

And the bike shouldn't try to pull forward when the clutch is disengaged. That will cause your hard shifting issues too.

 

Sounds like it may be too much end play on your shift drum. If you take the top cover off the Trans, look at the washer on the right side of the bike, I bet it is bent out

 

I would try adjusting fluid level in the primary and trying a little different of a clutch adjustment. Some bikes like a tighter spec on clutch adjust and some like a little looser.

Same with primary, mine shifts best a couple ounces less than what the manual calls for, and I still get plenty of primary fluid (15w-50) throwing around in there.

The above two items don't cost anything but a little oil, and if it solves the problem, then great. If not, move on to the other items suggested here. YD

 

Before you do all of the above try readjusting the clutch cable.

The reason I say that is because today I was out riding the Hill Country and suddenly my bike became really hard to shift.
Turns out the reason was the jam nut on the clutch cable came loose and readjusted it's self.

 

Completely agree based on symptoms....and I've had the exact same thing happen to me with the self adjusting cable.

 

Checked the jam nut and it is tight