So let me tell you a story about what happened to me on my way to work at 2000 hrs last night. I was on I580 east bound from Livermore Ca. I get on the superslab and go to shift and it doesnt go. I start to try and think did the lever get stuck or fall off or something? Well im doing about 65-70 at 4000 rpm and I realize that I can make it to work as my commute is pretty much all freeway then about a mile of surface streets with only 2 stop signs for a grand total of about 30-35 miles. So I putt along getting passed by just about everyone, as many of you bay area drivers know 65 on I580 is actually quite slow. So needless to say I get through the stop signs and get to work pull it in and dismount and find that the linkage had completely fallen off the transmission shaft. I get it back on to get to the nearest dealer this morning which thankfully is only about 5 miles or so. Get there and they tell me that the inner and outer primary has to come off to inspect the shaft and re-attach the linkage. The bike is only 9 months old so its warranty work for sure but is there anything I can do to prevent this from happening in the future?Is this common? I dont stomp really hard when I shift I dont think and I dont hot rod the bike so I dont know but any input would be appreciate it.

 

i assume your talking about the rod with one end near the shifter that goes back to the trans...if so, replace the two cheesy ends with hiems joints. you can buy them at a local hardware store in plain metal, chrome or anadized. or you can buy fancy ones from harley or j/p, dennis kirk etc. its a 5/16 standard thread. the shift linkage ends are very common about failing. im sure you can find alot of reading on it if you search "shifter linkage". i replaced mine with two chrome hiems. dont know why they have to pull the primary for that. but if under warranty....good luck with it

 

You may want to take a picture and post unless you think the fix Scooter1128 provided is going to work for you (it's pretty common). Based on your description it's hard to tell what broke - the "transmission shaft" you mention could be a number of things, based on how you are describing it.

 

It's not the heim joint. The heim joint connects to the tranny is what fell off. When you shift gears the shaft that actually comes out of the tranny is where the failure was. I hope that makes more sense

 

I "think" that you are talking about the vertical bar that comes up from the tranny and then attaches to the shifter linkage???? In that case, mine had the very same problem and I replaced it with a heim joint at both the front and rear end. The OEM linkage is comprised of a very unstable kind of connector.
Many options as to what kind of linkage you can get.

1HarleyGuy1

 

The lever that is attached to the shifter shaft in the transmission, is where his failure occurred apparently. Sounds like that lever came off the shaft. And yes, that would require the inner primary to be removed to get access. Hopefully it was just a loose clamp bolt that allowed the lever to fall off.

 

Guntoter has it right. They don't know if the spline is stripped or not so hopefully it will be fixed when I get it back

 

Sorry but I misunderstood the problem. Oddly enough, my bike just came back from a full tune/check-up and I learned that that same part on my bike had also come loose and worn. I'm happy to report that it was about a $40.00 fix. (2005 EGC)

1HarleyGuy1

 

Sounds like it may have been loose awhile and the result was messing up the spline. Doubt you will ever have that problem again. You will probably give your linkage a shake once in awhile to make sure things are tight. We all need to check around the bikes to make sure things are tight, more often.

 

If the spline on the shifter shaft has been torn up, the shaft will need to be replaced. The lever that mates to the shaft will usually tear up first but, not always.

On another note: Just had to tighten 3 allen bolts on the tranny end plate on my buddys bike as they were all loose and he was leaking tranny oil. These are the bolts where the exhaust bracket (2) mounts to the tranny. Check these regularly, as they are known to loosen. If they continue to loosen replace the lock washers and locktite the bolts.