I have a '96 Fatboy with about 55,000 miles behind her. I am second owner in which I've had the bike for 8 yrs. It is my 1st Harley and this is the 1st time for any major problems. Here's what's going on. A friend and I were out for a ride. When we were leaving a gas station and I was shifting from 2nd to 3rd gear, I suddenly lost my shifting peg as it fell all the way forward and rested on the footpeg. I got the bike home and researched my issues and came up with a broken shifter shaft inside the transmission. I called around and was given, out of this world repair quotes. One shop even stated that they really didn't want the job because it was so labor intensive. Now through a couple bad experiences of having other people wrench on the bike, I soon decided to do my own wrenching. I'd say I'm a mediocre wrencher, sticking to my service manual and going online for specific advice as I'm doing now. So, knowing that this repair was a little over my head, I figured I had no choice but to tackle it. So I ordered up a shifter shaft/pawl assembly along with gasket and seal sets that I would need for reassembly. The repair took me an entire weekend and that Sunday nite I felt ready for a test start and I was hoping for a test run. Bike started right up in neutral of course but when I pulled the clutch and attempted 1st gear the bike immediately stalled. I figured that the clutch must need adjusting so I did a "by the book" adjustment at the clutch itself and then when I went to adjust at the cable, I found that I had run out of adjustment. I had run out of threads on the adjuster and my clutch lever wasn't near where it needed to be. So I research this and purchase and install a new clutch cable. Problem solved and I'm ready again for a test run. Bike shifted properly Into 1st, I took off and into 2nd, no problem but that's as far as the shifting would go and that's where I'm at, about 3-weeks later. Ive got the bike tore down again with the top cover of the tranny removed. I've tried almost every suggestion to remedy but have had no luck. Bike shifted completely fine . before this repair job so I'm wondering if a reassembly mistake on my part could be the cause here or maybe this is something common. That is the reason I am here and posting this queston in hope that you good people will share some of your knowledge and advice on my dilemma. I will be checking back regularly for any response and thankyou all in advance for anyhelp.

 

You need to use paragraphs.

So let's get this straight. You replaced the entire shifter pawl assembly. Right.

When you did this did you do a shifter pawl alignment. Probably not which could explain why it only goes to certain gears.

Second is you need to do your clutch adjustment again. Sometimes the clutch push rod doesn't seat correctly the first time.