2003 Sportster gearbox removal
Thread Starter
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1st Gear
Joined: Oct 2015
Posts: 5
Likes: 0
From: portsmouth
2003 Sportster gearbox removal
Ok so i have fallen off my harley and think i have bend 2nd gear shift fork....
i was hoping someone could give me a rundown on how to remove the 'trap door' gearbox.
i have a manual but am a little confused about which special tools i will need (removing the main shaft etc)
Thanks in advance. Will
i was hoping someone could give me a rundown on how to remove the 'trap door' gearbox.
i have a manual but am a little confused about which special tools i will need (removing the main shaft etc)
Thanks in advance. Will
Thread Starter
|
1st Gear
Joined: Oct 2015
Posts: 5
Likes: 0
From: portsmouth
why i thought
I fell off while i had forward controls fitted.
Now i have put new peg on it and new shifter linkage
- but it now often misses while changing from 1st to 2nd (like being in natural but not as the lights not on - almost like missing 2nd gear) - other times it goes into 2nd fine
- when going from N to 2nd i always get a clicking grinding sound before it engages into 2nd
what do you think? will
Now i have put new peg on it and new shifter linkage
- but it now often misses while changing from 1st to 2nd (like being in natural but not as the lights not on - almost like missing 2nd gear) - other times it goes into 2nd fine
- when going from N to 2nd i always get a clicking grinding sound before it engages into 2nd
what do you think? will
Road Warrior
Joined: Jun 2012
Posts: 1,832
Likes: 67
From: Phoenix
My first thought is, start with the simple fixes and go down the list. I'd check your clutch adjustment. Does this happen downshifting from second to first? Any other gears? Is it hard to find neutral?
Road Captain
Joined: Sep 2015
Posts: 529
Likes: 13
From: wi
As others have said, check the easy stuff first.
If you need to pull your transmission, you'll know it by the chunks of metal that come out or stick to the drain plug when you drain the transmission oil.
If its not shifting easily or not staying in gear, if I'm not mistaken, those parts/problems can usually be fixed without removing the transmission when dealing with a 5-speed (4-speed trannies are a different animal).
If you need to pull your transmission, you'll know it by the chunks of metal that come out or stick to the drain plug when you drain the transmission oil.
If its not shifting easily or not staying in gear, if I'm not mistaken, those parts/problems can usually be fixed without removing the transmission when dealing with a 5-speed (4-speed trannies are a different animal).
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Thread Starter
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1st Gear
Joined: Oct 2015
Posts: 5
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From: portsmouth
Other things
Ok. So this weekend I will remove the primary cover and clutch and have an inspection (do you think that's is best)? Shall I look at pawl / detent ... If so how?
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Seasoned HDF Member
Joined: Apr 2010
Posts: 9,526
Likes: 7,864
From: Long Island, New York
Here is the video from Led Sled installing their kick start kit. At least it gives you a great over view of how to take it apart.
This of course is a last resort, do everything listed above first.
This of course is a last resort, do everything listed above first.