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2003 Sportster 883
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Discussion Starter · #1 ·
Hey people of the community, first post here, hoping to find some help. Ive been having issues shifting with my sportster for a while now, its right at 19000 miles so i figured it was the grenade plate making a mess of things. I changed my clutch and the spring plate was in decent condition. But taking the primary cover off i found a small piece of metal in the case. Im trying to identify this piece before i tear into it so i can try to have what i need before removing anything(thats never how it goes i know), but im just trying to get some insight. The issues i was having was that the clutch was finicky with second and neutral and sometimes would drop to neutral by itself. After riding for a while like this it started to not go below 3rd gear. I tried and tried even with the cover off and couldn't get it to drop down. Also i feel like its worth noting that the neutral light only works when i click into or past neutral and its just a momentary flick of light.
Thanks for the help, i will provide a picture of the metal i found in the primary.
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Gotta start off with the SRM is your friend!

That looks to be one of the primary covers alignment pins. Look at the perimeter of the primary cover, there is 2 or 3 large pocket holes those pins fit into. Matching pocket holes on the inner side. Some stick to the inner and some to the outer case when removing the cover. Then there's the lucky one that falls out, just to make the mechanic say "WTF are you?"

Good luck with your project! (y)
 

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Discussion Starter · #5 ·
Gotta start off with the SRM is your friend!

That looks to be one of the primary covers alignment pins. Look at the perimeter of the primary cover, there is 2 or 3 large pocket holes those pins fit into. Matching pocket holes on the inner side. Some stick to the inner and some to the outer case when removing the cover. Then there's the lucky one that falls out, just to make the mechanic say "WTF are you?"

Good luck with your project! (y)
I appreciate the reply, thinking back on it there were no alignment posts for the primary cover only the bolts and the two bushings for the two horizontal bolts.
 

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I appreciate the reply, thinking back on it there were no alignment posts for the primary cover only the bolts and the two bushings for the two horizontal bolts.
Looks more like a roller bearing, the alignment pegs are usually hollow spring things.
What year Sportster ?
From the picture, i couldn't tell if it's solid or hollow.
What's up with the end to the left side of the picture? It looks like a fractured guide or something. I would like to see a picture from the end. (The rough end) the machined end looks to be a normal chamfer (although a bit crooked). Certainly wasn't chamfered on a lathe. Need some end shots of this thing.
 
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Hey people of the community, first post here, hoping to find some help. Ive been having issues shifting with my sportster for a while now, its right at 19000 miles so i figured it was the grenade plate making a mess of things. I changed my clutch and the spring plate was in decent condition. But taking the primary cover off i found a small piece of metal in the case. Im trying to identify this piece before i tear into it so i can try to have what i need before removing anything(thats never how it goes i know), but im just trying to get some insight. The issues i was having was that the clutch was finicky with second and neutral and sometimes would drop to neutral by itself. After riding for a while like this it started to not go below 3rd gear. I tried and tried even with the cover off and couldn't get it to drop down. Also i feel like its worth noting that the neutral light only works when i click into or past neutral and its just a momentary flick of light.
Thanks for the help, i will provide a picture of the metal i found in the primary. View attachment 819309
Could this be the end of the clutch adjustment screw broken off the screw p/n 11752 ? Might be why the OP can't get the clutch adjusted !
 

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Discussion Starter · #8 ·
From the picture, i couldn't tell if it's solid or hollow.
What's up with the end to the left side of the picture? It looks like a fractured guide or something. I would like to see a picture from the end. (The rough end) the machined end looks to be a normal chamfer (although a bit crooked). Certainly wasn't chamfered on a lathe. Need some end shots of this thing.
Sorry brother thats the only pic i have. I left it on a towel and first thing my old man does when he comes to see what im doing is flick off the towel so its lost in the eternal desert.
 

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Solid with one "rough" end.
Not a guide pin for sure. I would look hard at Schmidty's idea of it being part ot the clutch adjuster.

Item #6 in this link. (says not available) But I would dig it out of the bike to ensure if it is broken or not. May have to hunt aftermarket for one:

Or go desert parts hunting with a magnet... So ya can provide both ends to a machinist so he can make you one. (About worth a 6 pack or so) (y)
 
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