03 Sportser 1200 transmission issues

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Sep 14, 2022 | 12:03 PM

RacingPoppa1

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Stage III

Joined: Sep 2022

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From: Cathedral City

03 Sportser 1200 transmission issues

I have a 2003 Sportser 1200 recently purchased, shortly after purchasing began to not shift into 3rd gear. I disassembled the primary to inspect the situation and found there to be a small clip (which holds the star shaped shift plate) in place (found shift plate to be bouncing around on the shaft) long story short I repositioned the shift plate and replaced the broken clip and everything is all good except that now I’ve got no 5th gear. Disassembled again to check positioning of the plate (adjusted positioning) reassembled and still no 5th gear… can anyone inform me of the proper positioning of the shift plate or provide any assistance or input (would be greatly appreciated) btw.. I have attempted to obtain a service manual for the bike however there’s apparently only one available in my state and they’re not sure if they can ship it to me in my area 🤔🤦‍♂️ Any input would be as I stated greatly appreciated, thnx y’all

Sep 14, 2022 | 12:12 PM

John Harper

HDF Community Team

Joined: Dec 2011

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From: San Diego, CA

It's not the Factory manual, but you might buy this:

https://www.ebay.com/itm/28495226200...Bk9SR6SN3s_nYA

John

Sep 15, 2022 | 10:09 AM

marcodarq

Grand HDF Member

Joined: May 2014

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From: florida

the shift star is only meant to go on one way! the pins in the drum have a specific shape that match the holes in the star. are they properly lined up?
m

Sep 15, 2022 | 11:39 AM

RacingPoppa1

Thread Starter

Stage III

Joined: Sep 2022

Posts: 3

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From: Cathedral City

Quote:

Originally Posted by marcodarq

the shift star is only meant to go on one way! the pins in the drum have a specific shape that match the holes in the star. are they properly lined up?
m

@ marcodarq.. correct, the star would only go on as aligned with the pins. However as far as the pin plate (actual transmission) there must be a particular positioning it needs to be in for all the gears to catch (unless I’m just an idiot lol) and there’s a totally separate issue within the transmission itself yeah? @ marcodarq thnx for the input.

Sep 15, 2022 | 01:55 PM

RacingPoppa1

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Stage III

Joined: Sep 2022

Posts: 3

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From: Cathedral City

5th gear

@ marcodarq.. in the process of upshift I can feel it try or start to catch 5th but when clutch is released it starts to catch but drops back down to 4th gear. Reason why I’m thinking it’s a positioning or an adjustment issue) perhaps there’s a way to adjust the arm that I’m unaware of. Idk, it will get figured out eventually lol preferably sooner than later.