| Author | Message | ||
     Shag9499 |
ok guys went for a drive the other day and she was fine. went to drop a gear to pass and no 4th all gone. tach shot up so i dropped to 3rd and she was fine got around the car and went to try 4th again to no avail so went to 5th. got her home no other problems. all other gears and neutral are fine. ive heard about the primary tensioner chunking and causing problems and im assuming thats the problem from the outside looking in but just wanted to see if there are any other problems to possibly look for. | ||
| Reepicheep |
Thats the side you will start with, and you should upgrade the tensioner regardless, but that sounds like a deeper problem. The good news is that, being an M2, you have a cartridge transmission in there. So you can pull the whole thing out without splitting the cases. I'm guessing a broken shift fork or maybe something wrong with the shift drum. | ||
| Shag9499 |
ok looks like ill be diggin in here soon. thanks reep. not sure if anyone has detailed the removal with pics and all so i may do that and post for future refrence. cant ever have enough pics for refrence imo. | ||
| Reepicheep |
The factory service manual is very helpful. You can take the clutch assembly, stator bell, and stator chain off as a unit. No need to take the clutch apart. | ||
| Shag9499 |
yeah i got the fsm. since im going to have the thing apart are there any recomended mods or improvements since ill be in there? | ||
| Reepicheep |
New tensioner, but that was on your list already. New metal primary gasket. If you pull the tranny, get a look in there and check your 5th gear drive assembly needle bearings (which stays captive in the case). | ||
| Bluzm2 |
Corey, Sorry to hear about your problem. I've got good news/bad news. I just saw this EXACT problem on a 2001 Sportster earlier this year. It was the sliding 4th gear AND the hold down clip for the detent plate. After I got his primary open and the clutch/chain/rotor off I saw the detent plate. I was hoping that was it. Not to be. After pounding the pins back in place and reattaching the detent plate with a new clip I clicked it through the gears. Still no 4th gear. Just spun like it was in neutral. I started to notice some metal fragments at the bottom of the gear case. Big chunks... I pulled the tranny, and gave it a quick once over. The shift dogs on the sliding 4th gear were totally gone. Sheared completely off, all 4 of them. I had to order parts and tear the tranny down and replace the gear. Warning.....the snap clips are a BITCH to get off. You have to remove most of the gears on both shafts to get to the 4th gear. Its the 2nd one in from the clutch side... Make sure you take GOOD pictures and be VERY careful when disassembling the 2 shafts. DO NOT inadvertently swap ANY gears. There are two that look identical but they are not. DAHIKFS This is not a hard job, just be VERY meticulous when you tear down and reassemble. The gear was cheap, only about $45 or so if memory serves. Brad | ||
| Shag9499 |
ok thanks Bluz. its gona be a few weeks before i get the garage in shape to work but once its good to go ill keep youins posted. | ||
| Shag9499 |
jim for some reason i cant see your post but anyway ill be tearing into it soon. garage is in order and am stocked up on lp to get me some heat out there. is thier anything in particular you are wanting to see? | ||
| Shag9499 |
ok a few months later lol. anyway got the tranny out. main problem is that number 1 gear on main shaft is shot. the "engagement cogs" my word not buells lol are shot it wont engage when in 4th gear. so thats prob one. prob 2 main shaft is wore about 20 to 30 thou where the rear or inner most needle bearing rides inside the splines on the 5th gear/output splines assemply. also that outboard support roller bearing ( pressed into the belt side of the tranny box) is a lil noisy just turning by hand. figure i might as well replace it as well. looking for parts for said items and possible upgrades while the primary is apart. i got plenty of pics that i will post soon but i wanted to get this up to start to get new stuff coming. | ||
| Reepicheep |
Been there done that. Replace the gears in pairs if you can... and you will need a monster pair of snap ring pliars (found some at sears) to pull that shaft. I got the 5th gear drive assembly out of the bike with home made tools... scary, but it worked. I couldn't get the needle bearings out of the assembly though, I took it to somebody with a hydraulic press and paid them 30 minutes shop time to press the old ones out and the new ones in. I've wondered since if it would have been possible to get those internal needle bearings out of that 5th gear drive assembly while still in the bike with some careful tool fabrication... | ||
| Shag9499 |
do u mean the actual 5th gear drive thru the bearing into the case? mine came out with a snug tug lol. or are u talking about taking the bearing out of the race on the outboard side? thinking i can get the needle bearings out ok one way or another lol. saw that its gona take more thatn the 9 dollar set of snapring pliers i have lol. im assuming and i know where that usually turns out but the bearings and gears stock sporster tranny numbers as far as reordering? wondering who caused this deformity of the gears???? wasnt me thats for sure. especialy that high up in the gears????? thoughts? all the other gears look pretty good not much visable wear. shaft is another story. none of this seems to be a common problem when scouring the archives a bit. improper belt tension for the outboard bearing but the inner needle???? | ||
| Reepicheep |
If yours is what mine is, the needle bearings inside that 5th gear drive assembly rusted and came apart, which damaged the output shaft of the transmission. That assembly gets poor lubrication, and is very sensitive to belt over tightening. You can now join the chorus of "run the belt scary loose!" So what I am talking about is taking out that assembly that contains the needle bearings... normally it has to press out of that big bearing that sits in the case, it can be a bear to get out. If yours came out by hand, I'm not sure if that is lucky that it came by hand, or a bad thing meaning that bearing was damaged. That bearing should be replaced regardless. So you take out that big 5th gear drive assembly, and press out those little needle bearings, and press in new ones. And replace the shaft (if damaged) and the engaging gears for the problematic popping out spot (the manual shows the power transfer path if that helps you figure out which pair). I don't know that the sporty gears were the same for all gears, I know the S1 had some changes over the years from a really wheelie happy 2nd gear (I think) to a more tame one (which most people understand to be a step backwards). | ||
| Shag9499 |
yeah im pretty sure its not a good thing that the 5th gear assembly just poped out. and im going to replace that big bearing for sure. now to find part numbers and order stuff. | ||
| Shag9499 |
also looks like the tensioner is updated. anyone have a pic of a stock one. the ball and ramp looks updated as well, mine looks like the muller one what are the differances there as well? pics? both improvments i was going to do but looks like someone beat me too it  | ||
| Shag9499 |
pic of gear  | ||
| Shag9499 |
pic of shaft  | ||
| Reepicheep |
yep. those are toast. The new shaft wasn't as expensive as I feared, though I don't remember how much it was... | ||
| Shag9499 |
ok cool saw a used tranny on ebay but the worn spot onthe shaft was almost exact as mine | ||
| Bluzm2 |
Shag, That's the gear... Same as the Sporty I did last year. I'll answer your email tonight... Brad |
