The 5-speed transmission was the standard for Harley Davidson bikes before introducing the 6-speed in 2006. But, particularly, the 5-speed transmission gets some common issues over time. They should be addressed and fixed when you notice them in your beloved two-wheeler.
So, what are the common Harley Davidson 5-speed transmission problems? A slipping clutch, issues shifting to various gears, and a shifter not returning to the center are among the problems. Jerkiness when accelerating and transmission oil leakages are also frequent issues with the transmission.
5-speed Transmission problems on the Harley Davidson significantly affect the bike’s performance. Read on to learn the problems and solutions in detail to keep your Harley 5-speed transmission smooth.
Harley Davidson 5-Speed Transmission Problems
The table below lists the common 5-speed transmission problems with the Harley Davidson and their solutions.
| Problems | Solutions |
| Not shifting to various gears | Bent shifter fork, replace worn shift levers, replace shifter pawl return spring |
| Clutch Slipping | Adjust clutch cables, replace clutch disk |
| Rough Acceleration | Replace transmission fluid Replace spark plug |
| Leaking Transmission | Replace worn seal |
| Gears grinding | Lubricate the bearings |
Let’s break down the points in the table in in-depth
1. Gear Not shifting To Various Gears
One of the problems commonly reported with the 5-speed transmission on Harley Davidson is not shifting to various gears. Some users had problems with gears one and two, while others with the other three.
Possible causes of the problem include a bent shift fork and a worn-out shift lever. The problem may also be caused by the shifter not returning to the center. Mostly, a contaminated or broken pawl spring may cause this problem.
Solution:
Solutions include repairing or adjusting the failing parts or replacing them. Use a manual to learn and adjust the shifter pawl or replace it if it’s broken. The buying and replacing costs of the shifter can range between $100 and $250.
2. Clutch Slipping
The clutch disconnects the transmission from the engine when the driver shifts and reconnects afterward. Without the disconnection, the driver will be unable to change gears.
Like most transmissions, the main cause of slippage in the Harley Davidson transmission is worn-out clutch disks. Another is a clutch contaminated with oil and grease or clutch cables that are too tight.
Solution:
Adjust the clutch cable and loosen them, but not too loose, as it can allow wear on the clutch disks. You can also replace the clutch disks, which costs $60 and $150 to buy.
The following video will guide you on how you can adjust the clutch cable
3. Rough Acceleration
While there are many causes of rough acceleration, the 5-speed transmission is a common cause of rough acceleration in Harley Davidson bikes. The users with the problem reported the problem causing the motorcycle to hesitate or jerk when accelerating.
Contaminated transmission fluid is among the common causes of rough acceleration. Also, a bad sensor, especially the throttle position sensor, and a worn spark plug are other causes. The two, among others, make the Harley Davidson evolution engine problems, too.
Solution:
Change the transmission fluid with a suitable oil with the manufacturer’s recommended 20W50 grade. If you suspect worn-out spark plugs, buy new ones for around $10 and replace the old ones.
4. Leaking Transmission Fluid
The transmission fluid lubricates the transmission and its parts and keeps them cool. When it leaks, the bike’s transmission can experience various mechanical problems, which, if not fixed, may cause issues.
Some users report the cause to be faulty seals or a loose cap on the transmission. The fluid may sometimes leak from the seal between the starter and the case. This problem is among the few common in the Harley Davidson Sportster years to avoid.
Solution:
Observe the leaking point on the transmission for a better chance of fixing the issue. Replace any worn seals on the bike’s transmission, and tighten loose bolts that may allow fluid to sip through.
5. Gears grinding
Gears grinding is another frequently reported problem with the Harley Davidson bike’s 5-speed transmission. The issue is known to happen when the gear is on neutral but sometimes on other gears.
A popular cause of the gear grinding problem is the inner primary bearing or the trap door bearings. The bearings may be unlubricated or poorly maintained, causing them to grind and produce noise.
Solution:
Lubricate the bearings with a manufacturer-recommended lubricant to prevent further damage to the transmission. You may need to check the transmission trap door, which, if cracked, can cause the noise and need replacing.
Preventing Harley Davidson 5-Speed Transmission Problems
Diagnosing and repairing Harley Davidson transmission problems is both time-consuming and expensive as it involves taking out lots of parts. Luckily, there are various ways to prevent these problems.
You can follow the following tips to keep transmission problems prevented.
- Ensure the transmission fluid isn’t low, resulting in parts wearing on each other.
- Make sure the engine doesn’t overheat. Overheating is a leading cause of transmission problems.
- Do maintenance on the transmission and other parts in the required time.
- Do repairs as soon as any transmission problem shows up to further damage.
FAQs
The following are the frequently asked questions on Harley Davidson’s 5-speed problems.
Q1. Should I Replace a failed 5-speed Harley Davidson Transmission?
Most times, problems with the Harley Davidson 5-speed transmission are fixable through repair. However, if there are many weighty transmission problems with high repair costs, replace them.
Q2. How Much Does Repairing Harley Davidson Transmission Cost?
The Harley Davidson transmission problems repair cost ranges between $100 and $500 for most of the problems mentioned above. However, the price can go as high as $2000, if several parts are replaced in the transmission.
Q3. How Long Does Repairing Harley Davidson Transmission Problems Take?
Depending on the problem, most transmission problems can take between 10 hours and a few days to repair. Most times, the repair parts availability determines the repair time.
Bottom Line
The article should help you learn and understand various Harley Davidson 5-speed transmission problems. Several solutions to these problems are covered to help you know what to work on when repairing.
While you can do some of the transmission repairs, most of them should be done by professionals. A professional may have a better chance of determining the cause and providing a solution. Also, there are several measures discussed that should help you avoid transmission problems in the future.