| Author | Message | ||
     Cyclonemike |
Hi all, I've been reading this site going on two years now and it's a great source of info. Haven't posted but a few times because I can usually find what I'm looking for with a "search". This time I'm kinda pressed for time and have a problem, maybe a big problem?! My '02 Cyclone started missing shifts last fri. I've hit "neutral" between just about every gear, not all the time but enough times to know something is wrong. I may be to blame. Here's the story. I'm from Ohio, staying out in Vegas with my brother because there's work out here. Last mon. morning I rolled the bike out of the garage, went in to get my helmet and heard a crash, yep it rolled off the side-stand and hit hard. Broke the clutch lever and slightly bent the shift lever. Everything seemed to still work. The Las Vegas Buell dealer didn't have a clutch lever so I ordered one from American Sportbike. Straighted the shift lever and rode the bike all week no trouble, until fri. Then it started hitting false neutrals. This week-end I put on the new clutch lever, changed the primary oil, adjusted the primary chain and clutch. Went for a ride and it seemed fine. This morning it was back missing shifts again!? It has 19,000 miles on it. Any ideas? Thanks in advance. mike | ||
| Reepicheep |
The 02 probably has the new primary chain tensioner (thicker back plate) so it is probably not that... There is a small deten't clip that holds on the plate over the shifter drum pegs... thats a part fairly notorious for failing... and that whole shifter pawl assembly sometimes needs adjustment, and the pegs in the shifter drum sometimes back out. You would have to pull the primary cover, then pull the stator, clutch assembly, and primary chain all as a unit (easy job but you need some big sockets and a primary locking chunk of aluminum or a sacrificial towel). Get the new metal primary gasket to put in while you are in there. Once you get it apart, it should be fairly easy to diagnose. If you were still in Ohio, I would help you  | ||
| Cyclonemike |
thanks for the input Reep. Not being in Ohio is my main problem at this point, I left the majority of my tools at home. I have a metal primary gasket already installed since I had it off last summer to pull the starter. I'll get my shop manual out and see about the shifter pawl adj. I hate to waste all this good riding weather out here. Do you think the tip over may have caused this?, just wondering why it ran fine for three days then started this crap. mike (Message edited by cyclonemike on April 02, 2007) | ||
| Reepicheep |
It could have. A left side tip over could drop a lot of impact on the shifter shaft, which is all connected up with the shift pawl assembly. | ||
| Cyclonemike |
well I went through the shop manual last night, not sure if it all makes sense, probably will be clearer when I actually have the primary cover off and can see the parts "in person". I have a couple more questions maybe you can help me with. I'm flying back to Oh. thur to spend Easter with the wife and kids. Do you happen to know what size the sockets are I'll need? I'll bring them back but I'm not going to tear things apart till I get back out here next week. Also do you have the dimensions for the locking bar?, maybe I'll just make one. Thanks again for the input. mike *how 'bout them buckeyes last night?!  | ||
| Reepicheep |
Bolt sizes are in the knowledge vault somewhere, and the manual gives dimensions for the locking bar. I mashed a piece of aluminum channel flat, and kept trimming it with a hacksaw until it worked. Do you fly into Dayton? | ||
| Jackbequick |
The primary locking bar needs to be 4-1/8" long, anything about 3/4" to 1-1/2" wide is okay. 1/4" aluminum would be good, 1/8th" is about as light as you want to go. You can slightly round the ends to match the sprockets a little if you want. Any material that will not deflect under the pressure will be fine, mine was made out of a fibreglas scrap from a boat hull. Jack | ||
| Cyclonemike |
Jack, thanks for the dimensions. I have some ss barstock at the house that should be perfect. I fly into Columbus thur night, and back out again mon night. mike | ||
| Cyclonemike |
Reep, sorry it's taken me this long to post up my thanks. I pulled off the clutch pack last week and the retainer-clip was off and in two pieces, bought a new one and put it all back together. I had to buy a new clutch cable as mine was broke at the threads going into the primary cover, from the tip over I'm sure. $78 for a cable at Las Vegas HD, seems a bit expensive. Got back on the road tue and it shifts great, thanks again! mike *loved the Ohio weather over Easter!* | ||
| Reepicheep |
*brrrrr* Sorry about that, we generally try and do better when we know company is coming That's a best case scenario, that is by far the cheapest piece you could have had failed in there |
