Is it normal for 03 883 sportster to have a distinct clunk when switching gears Also have to hold clutch in for a second or two so it doesn't chatter and has some knock ticking when eng warm?

Answer 1

Harley transmissions are known for the loud clunk. Make sure the primary/clutch oil level is OK. Or go ahead and change it out. You will need 24-26oz of sports trans fluid. There is a small pipe plug in the bottom of the primary case, not the one with the hex nut on it. Loosen and drain all the fluid into a container(discard old oil) Clean the magnet on the pipe plug. (there will be metal shavings on the magnet/thats OK) Replace the pipe plug, do not tighten all the way in, the thread is tapered. On the side of the case there is a small round fill plug with two screws holding it in place. (About the size of a silver dollar) Replace 24-26oz of sports trans fluid. That should solve your shift problems. To adjust the clutch cable. To have the clutch release where you feel the most comfortable. There is an adjustment barrel assembly in the cable housing attached to the front of the frame. Roll the rubber boot cover away from the adjuster. There you will find a hex body and locknut. Loosen the locknut,(1/2" & 9/16" wrenches) to have the clutch grab sooner: turn the hex body counter clock a few threads,(this lengthens the cable cover) test setting. To have the clutch engage at a farther out lever position, turn the body clock wise. The Harley-Davidson V-twin is a noisy engine. A whole bunch of nasty noise, like it is going to fly apart. Hope you have many years of good riding...