1993 Harley Davidson XLH Sportster 883 Logo
Anonymous Posted on Mar 07, 2010

My Harley 883 Sportster suddenly became stuck in 5th gear.

My Harley 883 Sportster (1995) suddenly became stuck in 5th gear, while I was out riding. When I tried to engage 4th gear, it seems to go in, but then immediately jumped back into 5th gear.
The bike is low mileage (approx 2500 miles).
No amount of force on the gear lever will budge it from 5th.
I had to ride home by slipping the clutch in 5th, which was horrible, particularly on take-off, fortunately the journey was only a couple of miles.
I could hear occasionally some 'new' clunking noises from the gearbox on the way home, I just hope this hasn't caused much damage inside the gearbox.

1 Answer

Anonymous

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  • Master 4,565 Answers
  • Posted on Mar 07, 2010
Anonymous
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Joined: Sep 22, 2009
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More than likely the shifter pawl has broken. Breaking in 5th gear is kind of unusual however, they usually break between first and second.

You'll have to remove the outer primary cover to look at the shifter pawl. It's partially covered by the clutch assembly.

Testimonial: "Thankyou for your help, I have been looking at an exploded drawing of the Sportster gearbox, so I can see what you mean."

  • Anonymous Dec 28, 2011

    COMMON FAULT 4SPEED SPORTY WORSE.....HARLEY STILL make the shiftr cam follower out of swish cheese,project engineerin makes said item out of stainless steel.......had org harley ones go this new stainless one as not gone yet give him a bell on 01384633759

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I didn't know Harley's had 5th gears. When you start slipping in the top gears, it's usually a worn out clutch - assuming you don't have the clutch cable so tight it isn't engaging all the way. Is there play in the clutch lever?
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I have a 2004 harley davidson 883 sportster and it keeps popping out of 2nd gear the guy i bought it from said that he replaced the gear and it just needs to be broken in?

No, sorry to tell you that you don't need to break a gear in. There is something not quite right in the transmission if it's jumping out of gear. If I had to guess, he probably broke second gear speed shifting the bike, then replaced the gear and go the shimming messed up and it doesn't have the correct engagement with the shifter clutch dogs. To repair this, you'll have to pull the transmission out of the case. If your mechanically inclined, this isn't that difficult but you WILL need a factory service manual to check the transmission to find out what is wrong. Heck, he may have put the gear in backwards. Some of them will work that way but they'll jump out when power is applied or let off.

Good Luck
Steve
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Motorcycle transmission

There is a spring inside the Primary that pulls the shifter back to the neutral position....it is broken......common problem with the Sportster.
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