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  #1  
Old 4th January 2014
islanddave islanddave is offline
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Default 2000 Buell Cyclone (Tranny Acting Up)

Ok .....my tranny started acting up this past year. Actually I got the bike this past year. It will slip then engage when I shift into second from first. At first it was only when the bike was cold then it would do it whether it was cold or hot. I suspect it is the clutch dogs on second gear. Is transmission work something that the average guy can do? I am handy and have rebuilt other engines but never a sportster.

Thanks Very Much David
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Old 4th January 2014
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xlron xlron is offline
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you can do it, not extremely complicated. And if you don't know yet, " you have a trap door" making it a whole lot easier than splitting the cases. Get the shop manual (sportster will do), and check out some YouTube vids . Replace the bearing in the door while you're at it. Buy or borrow the clutch removal tool, (ebay). And you will need a primary cover gasket. And... if you don't have the beefier primary chain tensioner shoe ( the white piece of plastic that you primary chain sits on, buy it. Check the trap door for cracks before you reuse it. Or buy a beefier trap door. One more thing: change your fluid before you do anything to rule that out. If you use synthetic, change to gear oil, and if you use gear oil change to synthetic. No diff, dig in.

Last edited by xlron; 4th January 2014 at 23:00.. Reason: add info
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Old 4th January 2014
islanddave islanddave is offline
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I guess one of my main concerns is that are there any tolerances that need to be adhered to............meaning is there any shimming involved to set the free play of any shafts or surfaces


Thanks Dave
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Old 5th January 2014
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There is a shimming process involved, but it is covered very well in the manual and is very strait forward. I can pretty much guarantee that the shims will go back in the same order they came out. Sounds like you need to eyeball the manual before you tackle this job though, so you'll have some confidence going into it. When you pull the trap, and have removed the primary ( external ) sprocket, you're pretty much going to pull the whole gear set as a unit, inspect it and set it aside, without messing with shimming. The situation you described in your first post means that more than likely you are only going to straighten out a shifter fork that is bent anyway. You can get the manual used from amazon, very reasonably.
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Old 5th January 2014
rubine rubine is offline
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Youll need a new set of retaining rings as well. As xlron said, grab a FSM and go over it, study that thing.
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Old 5th January 2014
islanddave islanddave is offline
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I found a manual locally for a 2001 should be the same right? I have been looking at the online manual at Bad Web but it's a pain to follow along on a computer plus it's for a 96..............don't know how many changes were made along the way.
What sportster specific tools will I need while I'm waiting for the manual to come in? What size is the engine sprocket nut? Will an electric impact wrench break it free? I'm doing all of this in my 10th story apartment!
I also have a very small base gasket leak at the rear cylinder, might be a good time to address this.....................maybe just spring for a 1250 kit from Hammer. Wanna do rear isolators too.
Thanks Dave
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Old 6th January 2014
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Default Nut?

My friend, you are just the kind of guy these bikes were made for (10th floor?). The only Harley specific tool you might need, would be the clutch tool, but you can make your own. Do a clutch tool search here on this site. I have just used a hammer and screwdriver on a corner of the sprocket nut, so don't know the size without going to the book. I believe I remember some kind of nut position retainer, so it will not be very tight anyway. As far as addressing a cly head leak, yeah, this would be the time to fix that as well. If it's a buell 1203, you're more than likely just inspecting parts and putting a gasket set in if you don't find anything out of tolerance. Rings, etc. I mean, what more can you do to make it go faster? Do you need to go faster than 135? A racing ecm will get you there if you're not hitting the mark. Long as the carb & pipe are up to snuff on jet sizing etc.....
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Old 6th January 2014
islanddave islanddave is offline
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Quote:
Originally Posted by xlron View Post
My friend, you are just the kind of guy these bikes were made for (10th floor?). The only Harley specific tool you might need, would be the clutch tool, but you can make your own. Do a clutch tool search here on this site. I have just used a hammer and screwdriver on a corner of the sprocket nut, so don't know the size without going to the book. I believe I remember some kind of nut position retainer, so it will not be very tight anyway. As far as addressing a cly head leak, yeah, this would be the time to fix that as well. If it's a buell 1203, you're more than likely just inspecting parts and putting a gasket set in if you don't find anything out of tolerance. Rings, etc. I mean, what more can you do to make it go faster? Do you need to go faster than 135? A racing ecm will get you there if you're not hitting the mark. Long as the carb & pipe are up to snuff on jet sizing etc.....
yeah 1203................really this bike is enough................I've never had this much fun on a bike. Stock muffler and a 3" hammer air cleaner, and up jetted the pilot.........and main................it runs great I just wanted to address the tranny issue. By the way it's a rear base gasket weep...................should I still be concerned? Does the engine need to come out to address this?

Yeah 10 th floor penthouse. I took the fuel tank and seat off and it fit in the elevator. I work midnights so no one was around to see at 3am on my nite off.

I have never worked on a bike before in so much comfort! Nice and warm, bathroom down the hall, tools at the ready, and computer by my side.
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Old 6th January 2014
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Again, read the book chapter concerning Cylinder head gaskets before you tackle that. It's not complicated either, but you need to pay close attention to torque spec's when it goes back together. There are some good You Tubes on cyl head gasket replacement also. Not necessarily on the sporty, but still basically the same.
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Old 6th January 2014
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There's no need for a clutch tool. The clutch can be removed without disassembling it.
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