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At what point do I stop putting up with the clunk of an old transmission? I'm running an early 80's 4 speed cowpie and the shifting has always been hard. Is it linkage or something more than that? I've always had to lean into it a bit to downshift. I'm running an aftermarket bracket the connects my linkage straight to shifter, bypassing the the pivot bracket. I have to apply less pressure but it's still something I have to bully. I have to rev up my RPMs to down shift into 1st if I'm not going slow enough.
Agree with Joe12RK, check the clutch adjustment (all of the adjustments, spring collar to pressure plate adjustment etc - not just the cable) first. If no luck there, you should check the fit of the clutch shell to the hub and if it is walking when the clutch is pulled in. Also check studs and fingers on the clutch hub for worn spots that keep the clutch plates from moving freely.
I have seen this in some not all i believe the shift spring in the hat are not exact in pressure from time to time and the shift drum with tighter springs snaps quicker so you get a clunk — have driven them with out it and with like you have and i am not a fan — the springs are like slinkies and you cant measure the tightness but if you decide to remove the hat also put a new bushing and fit it to just no movement - this will make it run true and drag a bit - you can re install the shift round with out the spring and see how loose it is in the hat - loose will make it turn quicker
If the linkage is good and the hat isn't sloopy I'll take the dremel and cratex bits points and polish the ramps inside & out on the shifter plate, doctor the detent ramps a hair for positioning plunger. Definitely smooths out the shift's and the neutral hunt is no longer a problem. Spots like this on the plate will cause hard shifting.
All great input...especially as regards Clutch Adjustment...which really is First...then, any really good Ironhead Sportster Transmission Guy, is yer Huckleberry!!
Good info here. The adjustment seems fine. No walking. No slipping etc. Even before I tore the bike down to chop it, it was a hard shifter. Admittedly I have not opened it up to look inside yet. My first "old" bike, so I wasn't sure how much to tolerate before thinking there was an issue to iron out.
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Old Cowpies
