2003 electraglide tranny issue

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Feb 9, 2019 | 03:45 PM

Shepdawg

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From: Louisiana

2003 electraglide tranny issue

2003 FLHT Electraglide- Transmission output seal was leaking on bike. Took primary cover off, removed primary chain, clutch assy., front belt sprocket, starter and compensating sprocket. Replaced main tranny output seal, shifter seal and gear shift lever on transmission side. Clutch assy was never taken apart. Before disassy. marked where primary tensioner was (was within spec before disassy). Reassembled and torqued everything per manufacture recommendations. Clutch is adjusted correctly and has been rechecked.
Bike won’t shift into 1st gear at all. Hard to shift into 2nd and beyond when bike is running. Transmission was not touched other than the clutch housing. Both the big left handed threaded nut and clutch retainer left handed nut were out on by hand, tightened to hand tight then torqued to 60ft lbs then torqued another 30-40 degrees. Compensator nut torqued to 150 ft lbs. Checked tension on primary chain and was in specs prior to putting cover back on. Anyone got any thoughts? The only other thing I. Did to the transmission was drain and refill the transmission oil.

Feb 9, 2019 | 09:27 PM

cncmike

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From: Fresno Ca

Shifting problems like that almost always end up being clutch adjustment related. Even though you have checked the adjustment there could still be a problem. With the derby cover off have you verified that the clutch diaphragm actually moves? Is it different depending if the engine is running or not? With the back tire off the ground and engine off you should be able to shift into any gear without even using the clutch by rotating the back wheel by hand. I have heard of the clutch cable ball not being seated correctly which would affect the adjustment.

Feb 10, 2019 | 10:57 AM

Shepdawg

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From: Louisiana

Yes. With the back tire off ground you can shift in all gear except for 1st. I have verified clutch is engaging. I pulled the derby cover off, loosened the retainer nut, backed the adjustment screw almost all the way out. Checked to ensure I did in fact did not have a stuck clutch cable (it was loose). I tightened the adjustment screw back in until it touched the push rod. Checked for free play in clutch lever-was good. Pulled on clutch lever and verified clutch was actuating.- yes.

Feb 10, 2019 | 12:10 PM

skinman13

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From: Texas

could be the trans shifter shaft might not be aligned on the input shaft where it should be...pretty easy to check, easy to miss..BTDT

Feb 10, 2019 | 01:14 PM

cncmike

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From: Fresno Ca

This might be a stupid question but is the shifter hitting anywhere, possibly the floorboard? Keeping it from moving far enough? It’s possible the shift arm is on wrong.

Feb 10, 2019 | 01:44 PM

Shepdawg

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Stage III

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From: Louisiana

I have looked at all of the linkages and none are hitting the engine, primary housing or anything else, so I’m good there. I’m guessing something came out of alinment when I replaced the shift shaft seal. Guess I’ll tear back down and inspect again. I’ll keep everyone up to date. Thanks guys.

Feb 10, 2019 | 06:27 PM

cncmike

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From: Fresno Ca

Try taking the top cover off the transmission and working the shifter. You can see the entire shifting mechanism. You might find some misalignment there.