ok so whats happening is about every 5 time or so I upshift or downshift into 3rd gear (and sometimes 5th) I pull the clutch in and the shifter doesn't move. Only way to get it to move is to rev the engine a few time and then it will shift. This all started last year after changing all my fluids. The same fluids I have used every year. Never ever done it before that. Not once. I rechecked the fluid amounts bike warm and straight up - trany dip stick not screwed in. Same as I always have. Read that maybe my primary was a litte to full so a drained off a few oz. same , drained a few more oz. no change. Also checked the clutch cable adjustment. Left about a 1/16" play. Over the riding season last year I noticed every once in a while if I started the bike in gear It would want to lunge forward just slightly even though I had the clutch depressed all the way. Over the winter I changed the clutch cable since its original 55k miles thinking maybe it was hanging up. Made no difference. This year I have adjusted the cable 3 times now. Seams to keep changing. When I had the trany side cover off while changing the cable I disassembled the inner and outer ramp and ball bearings, cleaned it all greased and reassembled. I did find there was some metal particals or shaving in thise ramps so I thought I found my problem but same thing after reassemblly.

why just 3rd gear and sometimes 5th

why did it start acting up all of a sudden

what should I check next?

 

I'm guessing maybe an issue with the actual gear or maybe even a worn/bent shift fork. Possibly even the fork my have come loose.

 

correct me if I'm wrong but I think the forks just slide on a shaft. not sure how they can come loose

 

The forks move the shift drum and they can wear out over time.
Your FSM will have the tolerances in it (I remember reading them but I don't remember what they are right now.)

 

Yes I agree that they can wear out but how did I go from no problems at all one day to having this problem the next day

 

You say you have adjusted the clutch cable...

Have you adjusted the clutch itself according to the service manual?

What model and year bike????

 

I have not adjusted the clutch yet. I'm not sure why I need to. It's a 96 Road King with 55k miles

 

https://www.hdforums.com/how-tos/a/h...c-guide-413073

Look here also.

 

Let's start simple. The shift lever not moving is not oil. What type of joints are on the ends of your shift rod. The typical side loaded ball or a hemispherical type aftermarket?

Sounds like you are actually getting it to shift by getting it close and letting transmission pull its self into gear.

If your adjustment is really changing, the throw out bearing is broken.

Most people who have never adjusted a clutch don't get it to the no play before the back off.. However, most any Harley after it sets a little will lug fwd if started in gear with the clutch pulled in. A wet clutch sticks.

Make sure you get the clutch adjusted correctly.

 

The reason you need to adjust the clutch is because you are having a shifting problem.