I have a 1990 FXSTS. My shift pawl spring broke and I took everything apart to replace it. I used the Baker Anti-Overshift Ratchet lever.

I've put everything together 4 times and each time I can't get it to shift correctly. Depending on the angle of the shift drum during assembly, I'll have 2nd through 5th, but it won't downshift into neutral or 1st. Or I'll have 1st and 2nd and it won't shift into 3rd. Either way when it gets into 2nd gear the shift drum seems to not want to rotate anymore.

Everything seems to be lined up correctly. I'm using the service manual and parts catalog as references and there's a couple really detailed videos on Youtube and it looks like everything is correct. I double checked the shift forks to make sure they're in the right place.

I've tried assembly 4 times and each time it's either got 1st and 2nd, or 2nd through 5th. I'm sure it's something little that I'm overlooking.

Any suggestions?

 

I have to confess that I had my spring replaced by an indy when it broke, way back (I've owned my '90 from new). Hopefully one of our experts will be along soon with the magic bullet. Best of luck.....

 

if you have an your to kill:


quite a few things come up if you google it.

 

Wow, I knew it was something dumb that I was overlooking. One of the retaining rings in the trap door wasn't fully seated. This caused the layshaft to be off by a tiny amount causing the trouble with second gear engagement. Just dumb luck that I saw it the retaining ring on the layshaft looked slightly different than the ring on the mainshaft, and then I realized it wasn't properly seated. Got it seated correctly, and everything back together, and it shifts fine. That was a lot of trial and error. More error than anything else. I'm surprised they let people like me handle tools.

 

All by yourself alone - well done!

 

And some people say this forum is going downhill!

 

OP can go uphill now!

 

I had the same issue after I just rebuilt my trans. It turns out, I had an extra spacer between the countershaft 1st gear and countershaft 4th gear.

I had to disassemble the whole thing and remove the spacer.

I bet neither you, nor I will EVER make those same mistakes again. LOL

I'm glad you figured our what the issue was.

 

I had one come in once and it was missing 4th gear...turns out the "repairer" had transposed a spacer on the layshaft with a gear....it was fun taking his money!

 

So, when I was putting everything back together, I used all new gaskets. But with the multiple attempts, I pretty much ruined the primary cover gasket which is now leaking. A new one from J&P cycles just arrived in the mail today. I got the same brand as I used last time: "Genuine James" Both times the gasket came with two washer shaped gaskets. What the hell are they for?