I have a Jim’s 2384 shift assembly kit that I never used. 90$ shipped. Also an article on how to do install without removing transmission.

 

@Turboprop has the best info on what the best upgrades are.

 

The spring is still available from HD, about 4 bucks.

You will be removing the gearset from the transmission do do this job.

You can upgrade the shifter drum and pawl by using an OEM shift drum and pawl from a 2001 or later 5 speed, probably for a lot less than 380 dollars.

 

Ok I’ll look up those part numbers, there was a bit of slop/ play in the shifter too I guess it needs new bushings too. Anything else to look for with 42k miles on it?
And yea I’ve read the sticky thread 🧵 m replacing the pawl spring. I’m on the fence about tackling it myself. I just finished finding and repairing all the electrical gremlins and poor wiring done by previous owners. Happy to rid myself of that headache.

 

The hardest part of the gearset removal is removing the components on the left side, clutch, compensator, inner primary cover, inner primary bearing, transmission sprocket. That is where the bulk of the work is, and is the area where you will need some special tools.

 

Couple of my buddies have the necessary specialty tools. I’m trying to make sure I have everything I’m going to need to get it done bc my work area at home isn’t going to work for this job. I can’t leave the bike in pieces waiting for parts taking up space at either of the garages I have at my disposal so ideally I’d like to have anything potentially worn or in need of replacing to be on hand

 

i just did mine.....make sure the pawl shaft splines are in good condition....otherwise replace it ....maybe replace the bushing the pawl shaft goes thru if its sloppy..as for special tools you only just need the main bearing puller/installer tool and a new main bearing if its scarred up....new big rear primary seal..shifter shaft seal...other seals/bearings at descretion....trap door/lid gaskets....i was lucky and got a used shifter pawl and drum set on ebay that was old/new stock... that looked barely used....got the good style billet shifter forks too....one of mine was scarred bad...but still worked.

 

no possible way to know what, if anything needs replacement,, without actually having it apart and in hand..
i can guestimate what a job will most likely need,,, and im really good, but, im rarely dead on,,, something missed or not needed.. the best method although not the least expensive is get a rebuild kit, and the shifter spring,, or aftermarket shaft assy..

 

I’m not overly concerned with cost. Obviously would like to try to save money where I can. I definitely want to update the drum and pawl spring assembly to the newer style. Pretty sure the shaft and bushings need replacement too. Ill change the shifter forks as well. I guess I should take the upper cover off and hope none of the pieces of the spring got in the gears. Hopefully I’ll get it done this weekend or next. Then it’s on to finding a solution to the air fork system since I’m not a huge fan of it.

 

Looking at the components in the Jim's kit, that bushing at the top next to the spring is the one that goes in the case for the shifter shaft to ride in. I have the Harley part number stashed away somewhere if I can find it.. There are 2 different ones, one longer than the other. I used the Jim's tool to remove and install the new bushing. Makes it easy to get it right. No measuring, just let the tool do it.

Did you have a look at their instructions? It says their kit is for all BT Shovel and EVO 5 speeds from 80-99. By that, you should be good to go. With the kit, or with the Harley stuff if you can find it as a pile of parts.

I'm looking at my parts book and comparing it to Ronnie's page for a 92FXRS, most of my shift mechanism internals were the same as yours. The support blocks and needle bearings were the same. Shift forks and shafts were the same. Even the shifter shaft lever with pawl and ratchet stuff was the same. The shift drums were the only major difference.

I did this about 8 years ago, one of the better mods I've done to my bike. Here is a link to when it was going on, sorry not much detail. In addition to the shift drum and the pawl assembly, you would need the pillow blocks, as they do away with the plunger detent in favor of the roller detent. I think my total cost was about $125, not bad.

Want to upgrade Shifting

Are all the upgraded internals a direct replacement into the transmission of my 2000 Lowrider. It shifts OK between gears, but neutral is hit or miss. More miss when it gets good and hot. What was the first year that incorporated all the improvements? It looks like 2003 for sure, maybe 2002...

www.v-twinforum.com

If you could find a take off shift mechanism from somebody that upgraded to 6 speed internals, that would be best. Looks like you could go all the way from 01 up to 05/06 for a donor bike. I got mine from online auction. Everything was stock Harley parts and fit just like they were always in there. I reused my shift forks and shafts, they were in good shape. I did buy the bushing from the dealership. I also needed the new centering screw. You might need to do some further research for the neutral switch for your FXR. They go from always in contact with the drum to only in contact when in neutral, less friction for shifting. The only problem with my install is I get a neutral light in 5th too. Probably has something to do with a difference in top covers.

 

Great info thank you! That answers a lot of the questions I had. Hadn’t seen anything in my reading about the neutral switch I’ll look into that.