2003 1200XL S rolling clunk problem
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3rd Gear
Joined: Jan 2018
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From: Davie, FL
2003 1200XL S rolling clunk problem
My problem is not the "kick it in first gear from a stop clunking", it is when I release the clutch from a stop and start rolling. Symptoms are with the clutch fully released and rolling in first gear, RPM's increase slightly as if there is no load on the motor because there isn't. Then just as quickly, she will clunk, reengage and be on her merry way. This mostly happens when cold but has happened when hot. Replaced clutch, (steel and friction plates,spring) to no avail. It needed a replacement anyway, bike had stock clutch with the grenade plate but it was intact. Previous owner told me he had the stator and rotor replaced. Bike has 15,000 miles on it and I want to keep it. Anyone ever had this happen to them, this is a first for me. Any insight would be a help. Thanks
Stellar HDF Member
Joined: Aug 2009
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The dogs on countershaft 3rd and slots countershaft 1st are worn. They slightly jump out of gear and then back in. Somewhat common on early 2000's bikes. The solution is to replace the gears with new ones that have the update on them (can't get the old ones now anyways).
It is usually worst when you shift in to first gear when it's cold because of the thicker oil and higher rpms associated with a cold start.
It is usually worst when you shift in to first gear when it's cold because of the thicker oil and higher rpms associated with a cold start.
Stellar HDF Member
Joined: Aug 2009
Posts: 3,212
Likes: 212
It’s not really a danger. Mines got over 80k mikes and has done it for a long time. Ways to reduce it are be rolling before clicking in to first gear, make sure it’s a solid shift, and lower your rpm down to idle speed before clunking in to gear.
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