Whenever I am doing a lot of around town, heavy traffic & lot's of shifting, I get a pretty audilble klunking when shifting between 1st and 2nd. It rarely
happens after I been on the highway for 30 minutes or more. Does this happen to anyone else? Anyone know a fix? It's an '02 and I've had the problem since it was new. The dealer thinks it shifts smooth (read as no help to me!).

Happens to me. I have never had a satisfactory explanation really, and it is not how I shift. It happens sometimes and not others. Sometimes it is slick and snicky, other times first to second positively crunches

Me too. Normal for an '02 I am guessing. My bike has 1200 miles and has always done it. I can lessen it by really throwing some boot into it when upshifting from 1st to 2nd. Also happens less when on the throttle (power shifting).

ttt (As Kaz would say!)

Now we have more members, can I get an indication of who else has changes from 1st to second frequently but irregularly clunking or actually grinding?

I have been really careful and observe my technique closely, varied revs and acceleration/deceleration on shift, etc but I can discern no pattern. Sometimes it is as slick as anything, other times I flinch at the sound. It's making me perpetually nervous on first to second gear changes and I am concerned about the damage it is no doubt causing.

Help and input please?

ttt (As Kaz would say!)

Now we have more members, can I get an indication of who else has changes from 1st to second frequently but irregularly clunking or actually grinding?

I have been really careful and observe my technique closely, varied revs and acceleration/deceleration on shift, etc but I can discern no pattern. Sometimes it is as slick as anything, other times I flinch at the sound. It's making me perpetually nervous on first to second gear changes and I am concerned about the damage it is no doubt causing.

Help and input please?
I do Not Want to FREAK You out my Friend but if You have a Very high HP V-rod then You would be STREESSED!!!!2 GEAR was what Broke in My Trannsmission on the Turbo Bike! :surrender

Karl
Mine is exactly the same! I'm going to mention it (again) when I get it serviced on Saturday - though this is a new dealership so maybe someone will take notice. Mine is also an '02 and I got even more worried when I rented one in the US that was really smooth (so it can't be me!). But that was an '03 so maybe it is an '02 thing. It's strangely reassuring that others are experiencing the same problem. Mine sometimes does it in other gears too!

I think it has something to do with the way the gears are cut. You can minimise this by changing at select revs. You would need to just work it out for your style of riding and particular bike.
(I have found it changes best at slightly higher or lower revs than what normally feels right to change. If that makes sense.)

Mine does it when I "2 finger" the clutch instead of using all 4 to operate it. Using 2 fingers, the lever comes back and hits my little and ring finger. It seems to shift better when I use all 4 fingers to work the clutch.

Mine is an 03 Christine.

I have experienced the same things with mine, I have over 20k on it now an haven't had a failure......knock, knock...

Happens to me. Don't like it. Nature of the Beast..

Every Harley I have ever had does this and I've never had any problems

OK - you need to clarify... Are you talking about a clunk when you shift from first into second, or from second into first?

Because there is a big difference, and a quite different solution to the problem, depending on which it is your talking about.

If its when you are downshifting from second into first, the simplest solution is to learn how to blip your throttle, matching engine revs to rear wheel speed.

If its when you are upshifting from first too second - then the problem is most likely that you are taking too long on the upshift, and the engine revs are dropping too much when you do it. Just practice till you can do it a little faster, and use a more "positive" action with your toe, just to be sure you don't leave it in neutral (done that a few times myself - embarassing, but rarely fatal...)

25k+ miles on my '02 and she's always made a bit of noise from 1st to 2nd.
Ka-Chunk!
Ain't that part of what lets you know you're on a Harley? :)