1996 fatboy, inner primary seal was leaking so i bought a chrome inner primary, replaced all the seals bushings, bearing. shifter shaft seal, trans seal. new belt. i adjusted the clutch like this. i released all the slack in the cable, then i loosened the clutch adjusting nut, ran the bolt in till it was loose, then backed it ut till it made contact then went 3/4 turn more counterclockwise and locked it down. then adjusted cable till the slack was almost gone. bike was in nuetral and fired right up. shifted in first, took off shifted into second and when i tried to downshift it wouldnt go. it shifted up but not down. now its in fifth and will not downshift. So im lost . im pretty sure i put everything back correctly. i didnt disassemble the clutch, i removed it as a unit. any ideas? i adjusted the primary chain like the book said .

 

Should be....slack cable, loosen jamb nut, screw in rod till just makes contact, back rod off 1/2 turn. Tighten jamb nut. Adjust cable to achieve 1/16" clearance between clutch lever, and perch.......steve

 

the clutch seems to be working. it freewheels when i pull the clutch in. and grabs when i let it out but i cant down shift the tranny at all?

 

maybe shift pawl out of adjustment. did it shift up easily?

 

when i first took off it shifted normally. it upshifted fine. i kept upshifting thinking it would downshift but it didnt. i guess it could be out of adjustment but all i did to the tranny was replace the shifter shaft seal and the main shaft seal.

 

Is your floorboard interfering with your toe shifter when you're pushing down on the pedal?

 

Any chance at all that it is something really simple like a loose shifter arm at the transmission. The arm at the transmission with the one Allen bolt.
Or
That either the arm at transmission or floorboard is misadjusted.

 

Not hitting the floorboard. I just put the shifter back on. I had marks for reference. I will look further tonight after work. Any chance starter could hang up and put pressure on it to not shift?

 

Something is stopping the shifter mechanism lever on the tranny from going as far forward as it needs to, to complete the downshift. I'd start there.

 

the shifter arm behind the primary, is on correctly and is free, will not down shift. i think i may have a bigger problem. it doesnt sound right when i start it. you know how sometimes the starter will kick back and make some racket, thats what it is sounding like. im gonna take the primary cover off and inspect.