Tranny Issue
Thread Starter
|
Advanced
Joined: Dec 2012
Posts: 61
Likes: 0
From: Southern California
Tranny Issue
Hello
I have a 2005 Roadking Police with 50,000 miles. It has a weird deal it does maybe once a day. If you are going uphill after you shift from first to second it feels like it pops out of second then goes right back into second all by itself. You don't have to touch the shifter it just goes out and back in. Then it's fine. It may happen once a day and it's maybe one second after you shift into second gear. And it pops out and back in very fast. I'm thinking the gearbox forks or gear dogs? The local shop here says the Rev Tech 6 speed conversion may be the best option. He say he has done about 10 of the newer Gen 3 ones and they all were perfect. I know the old ones had issues. He also mentioned the clutch but that does not figure in my brain with the issue mostly going into 2nd. I did forget to mention that it did it once shifting into third also. Same popped out and back in. Anybody had this????
I have a 2005 Roadking Police with 50,000 miles. It has a weird deal it does maybe once a day. If you are going uphill after you shift from first to second it feels like it pops out of second then goes right back into second all by itself. You don't have to touch the shifter it just goes out and back in. Then it's fine. It may happen once a day and it's maybe one second after you shift into second gear. And it pops out and back in very fast. I'm thinking the gearbox forks or gear dogs? The local shop here says the Rev Tech 6 speed conversion may be the best option. He say he has done about 10 of the newer Gen 3 ones and they all were perfect. I know the old ones had issues. He also mentioned the clutch but that does not figure in my brain with the issue mostly going into 2nd. I did forget to mention that it did it once shifting into third also. Same popped out and back in. Anybody had this????
Road Captain
Joined: Aug 2011
Posts: 538
Likes: 3
From: Florida
maybe consider a new title for the thread?
The shifter pawl inside the transmission probably needs to be adjusted. If its not adjusted correctly it doesnt turn the drum far enough into the next gear and will cause shifting issues. I would definitely try this before switching to a revtech.
Its a fairly simple adjustment, but you have to remove the top cover of the transmission to view the pawl and measure the adjustment. If your mechanically inclined and have a shop manual you shouldnt have a problem. If not, it shouldnt be more than an hour labor (maybe 2) at your local indy.
The shifter pawl inside the transmission probably needs to be adjusted. If its not adjusted correctly it doesnt turn the drum far enough into the next gear and will cause shifting issues. I would definitely try this before switching to a revtech.
Its a fairly simple adjustment, but you have to remove the top cover of the transmission to view the pawl and measure the adjustment. If your mechanically inclined and have a shop manual you shouldnt have a problem. If not, it shouldnt be more than an hour labor (maybe 2) at your local indy.
Road Captain
Joined: Aug 2011
Posts: 538
Likes: 3
From: Florida
And FWIW that harley 5-speed gearset is damn near bulletproof, so i doubt its the gearset. Try to adjust the pawl first. If it ends up being the drum or forks, then just replace those. That saves you $$, time, and labor.
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
Last edited by Frankenbagger; Dec 11, 2012 at 01:56 PM.
Thread Starter
|
Advanced
Joined: Dec 2012
Posts: 61
Likes: 0
From: Southern California
And FWIW that harley 5-speed gearset is damn near bulletproof, so i doubt its the gearset. Try to adjust the pawl first. If it ends up being the drum or forks, then just replace those. That saves you $$, time, and labor.
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
And I'm new here so I'm sure this is in the wrong place ha ha!!! Looks like I may have lucked out with you guys anyway!
Road Warrior
Joined: Sep 2006
Posts: 1,826
Likes: 87
From: Cookson, Ok
And FWIW that harley 5-speed gearset is damn near bulletproof, so i doubt its the gearset. Try to adjust the pawl first. If it ends up being the drum or forks, then just replace those. That saves you $$, time, and labor.
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
I bought a 2005 gearset out of a box of parts in a swapmeet (unknown miles) covered in dirt for $40, ran it through kerosene a few times and installed it in my EG. That was 2 years, 2 motors, 2 trips to deals gap, and one weekend with ZERO fluid (oops) ago. I still beat the snot out of it daily with 100+ft/lbs, powershifting and all...
Road Captain
Joined: Aug 2011
Posts: 538
Likes: 3
From: Florida
I was an idiot and tried to pull the mainshaft race off with a homemade "puller" that was pushing against the transmission case. I ended up pulling the whole mainshaft bearing out of the trap door, breaking it. The gearset was still fine and I could of pressed it into a new trap door ($170 from harley), but at $40 to replace the whole thing and have a spare set of gears why would i go through all that work?
Long story short - I damaged the old one while working on it, had i not done that It would probably still be in the bike.
It is still possible that its the dogs/forks or maybe even the drum or pawl, but most of these can be replaced without pulling the gearset and MUCH cheaper.
Long story short - I damaged the old one while working on it, had i not done that It would probably still be in the bike.
Thanks!!!! I appreciate the tip!!!! An adjustment makes more sense. I worked at a Honda dealer back in the 70's while in high school. I never saw a transmission jump out of gear and go back in by itself. Worn dogs normally cause just a jump out of gear. And I agree, staying with the 5 speed OEM gears seems better. 6 gears in the same space means less meat on the gears.
And I'm new here so I'm sure this is in the wrong place ha ha!!! Looks like I may have lucked out with you guys anyway!
And I'm new here so I'm sure this is in the wrong place ha ha!!! Looks like I may have lucked out with you guys anyway!
Last edited by Frankenbagger; Dec 12, 2012 at 10:47 AM.
Trending Topics
Road Warrior
Joined: Sep 2006
Posts: 1,826
Likes: 87
From: Cookson, Ok
Thanks Frankenbagger, that was good info. I was shown a trapdoor that the bearing had been pulled through and they aren't very sturdy. I was told the aftermarkets have a thicker wall backing the bearing and even a botched clutch adjustment can possibly pull it through the Harley trapdoor.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider
Verdad Gallardo
The Best and Worst Harley-Davidson Moves of 2025
Verdad Gallardo
Stellar HDF Member
Joined: Aug 2012
Posts: 2,664
Likes: 184
From: Indiana, USA
The 5 speed shift drum is more than generous on the in and out ramps for all but 4th gear. 4th is the only gear where you slip in and out of gear in a few degrees rotatation of the drum.
The shifter pawl adjustment is easy enough if you are patient. Your bike is several years old so the shifter linkage, pawl, drum bearings and detent have some where. Before adjusting the pawl, remove the drum and check the ball plunger that fits in the detents for each gear, Plunger is in right side drum carrier Easy enough to replace and will help to guarantee the drum is sticking in each position for each gear. After you reassemble the drum you should follow the directions for placing in the proper gear and adjusting for equal pawl clearance side to side with the plunger in the detent. Been awhile since i did it but seems to me is is 3rd gear and you will need a ground short allen wrench to fit between the adjuster and the inner primary. Can't remember but is was somewhere between a 3/16 - 7/32 - 1/4 hex key ground to about 3/4 OAL on the short leg.
The shifter pawl adjustment is easy enough if you are patient. Your bike is several years old so the shifter linkage, pawl, drum bearings and detent have some where. Before adjusting the pawl, remove the drum and check the ball plunger that fits in the detents for each gear, Plunger is in right side drum carrier Easy enough to replace and will help to guarantee the drum is sticking in each position for each gear. After you reassemble the drum you should follow the directions for placing in the proper gear and adjusting for equal pawl clearance side to side with the plunger in the detent. Been awhile since i did it but seems to me is is 3rd gear and you will need a ground short allen wrench to fit between the adjuster and the inner primary. Can't remember but is was somewhere between a 3/16 - 7/32 - 1/4 hex key ground to about 3/4 OAL on the short leg.
Banned
Joined: Mar 2012
Posts: 11,232
Likes: 16
From: Socialist Republic of the USA
Sounds like the same problem I just had fixed. I had 2nd and 3rd gears replaced. There is a guy selling a 5 speed in the classifieds, just the gear set. Said they have 21K on them. I would have bought it but did not get a reply back from him in time. Also had a fork that was worn. The parts were $318.00 for mine and now shifts/runs like new. I was having cams (Andrews 37) put in at the time. While the primary cover was off the stator looked about toasted with a burnt smell so had that replaced as well.