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Sportster Motorcycle Transmission, Clutch, Primary & Secondary Drive Transmission, Clutch and primary or secondary drive problems, advice, and/or how tos.

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  #31  
Old 1st May 2019
iNSaNeSHaNe's Avatar
iNSaNeSHaNe iNSaNeSHaNe is offline
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Sorry to here it is still binding somewhere.
It could be just the finger-rollers. I actually have mine apart as of a few hours ago to fix a hard shifting issue before I tear it up. I figure it is just the rollers are worn because I have had this happen before once or maybe 20 times..
I don't use the rollers for a sportster I use the ones for a cow-pie 4 speed. They are longer and you have to cut them down, but the flat where it rides on the fork is flatter where on the sportster it is more tapered. the flat edge gives more support on the fork and aligns better in the worm plate.
I just cut the length to the width of the shift plate. It makes the trans shift better and the rollers last longer.
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  #32  
Old 1st May 2019
CDeckner CDeckner is offline
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Well i’ve Checked and rechecked everything. Something is clearly binding when the trans is installed in the cases. I just have no clue what at this point. I feel like I’ve checked ore replaced everything at least twice. At this point I’m about to throw in the towel and take the bike into a local shop and have them fix it.
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  #33  
Old 1st May 2019
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I really wish there was some way to see what is happening.
Is there any way to get a picture or a video of the trans out to show it in neutral and as it shits into 2nd. on the bench.
Since I have mine out I am looking for what could be causing your problem by looking at mine.
Unfortunately, I have had mine apart so many times I should have a zipper for access..
I cant really explain everything about these but I can tell you with yours they seem to work better on the looser side of specs.
See what you can do about getting a pic or video, with it out on the bench.
How do you shift it when on the bench , testing the shifting.
I have the trapdoor locked in a large vise and I use a 3/8 extension to operate the shift mechanism. The square fits nice in the fork of the shifter tower. It's easy to shift it slowly when you use a long 3/8 extension
You can then watch the spacing and the operation more easily.
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  #34  
Old 1st May 2019
Four Speed Four Speed is offline
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Dang. I thought iNSaNeSHaNe had it. We will get there I am sure.

I agree with iNSaNeSHaNe that you need to systematically check the shifting and shimming etc. A video will help a lot.

Remind me, do you have the HD destruction manual to check specs and shimming?

OK. Here is one to check in detail. When you get back in check the rollers are able to run smoothly all the way round their track.
Typically the slop on the camplate shaft causes it to shift off axis during shifting and as it does the rollers are pinched causing
flats to develop - they should be round. The solution is new rollers, careful cleaning up of the tracks and bushing the camplate
tower with a thin walled bush to keep things aligned.

Have we discussed wear on the shifter forks yet?
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  #35  
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CDeckner CDeckner is offline
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I’m going to be away from the bike for about a week. I’ll try and get a video and some pictures of everything when I get back from my trip.

I have a HD service manual and a Clymer manual

There shouldn’t be any wear on the forks as they are new steel forks. I’ve checked them for interference with the gears and they’re all good on that respect.

I appreciate all the help. I’m getting frustrated and I’m sure i’m Going to feel dumb when it’s something super simple that I missed.
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  #36  
Old 1st May 2019
Four Speed Four Speed is offline
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The break will do you good. Come back to it with fresh eyes and you will find it.

Incidentally have a read of iNSaNeSHaNe's lastest posts, on his WTF thread. Could be relevant.
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  #37  
Old 12th May 2019
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Alright so I’m back from Hawaii. I was able to rent a softail and my wife and I toured around the island for a day which was spectacular especially climbing up the saddle road in the clouds up to Mauna Kea.

I was looking at the way 2nd gear was shifting and I noticed that the fork was popping out slightly while it was shifting between 1-n-2-3. When I held the tip of the fork into the gear while shifting it shifted like butter but allowed to do its own thing it was binding the roller. I’m wondering if the face of the shift cam is slightly bent from when this bike was laid down. I’m going to try and find a replacement on eBay before I order a new vtwin one and see if that fixes it.

I ran some 320 grit over the tracks the roller run in to clean up any burrs and that didn’t change the issue. The mainshaft fork doesn’t have the same issue with running in the track.
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  #38  
Old 12th May 2019
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Do me a favor and see if the trap door is cracked where the fork rod slides into it.
It'is suppose to be a tight fit. I have 2 cracked ones from my blown gears and other endeavors.

I have smacked a curb and spun the sift shaft right off at the pinned ball, and even after my hi side where I broke the primary cover I never have bent the worm plate. It would be a first but anything is possible.

Just a thought but when you put the trans in place how easy is it to line it all up.

I have a strange procedure, but it works for me.
I put the shift shaft ball in the fork of the tower and choke up on it with my left hand holding it tight to the door then with my right hand I grab the splined clutch gear and maneuver it in place. I usually have to move the door around a bit to get the fork pin in the case.

If you can ever get us a few pics or a video it would help a lot in diagnosing the problem.
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  #39  
Old 12th May 2019
Four Speed Four Speed is offline
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Quote:
I have a strange procedure, but it works for me.
I put the shift shaft ball in the fork of the tower and choke up on it with my left hand holding it tight to the door then with my right hand I grab the splined clutch gear and maneuver it in place.
iNSaNeSHaNe, not so strange, I pretty much do the same. I find it best to lean over the frame from above when doing this. Thankfully I have had less practice than you.

A damaged or worn shifter fork will not help. One of the riders on here braised and reground the tips back to specification. You could usefully check the shimming careful again.
I take it that you have the support plate to check the shimming, as per the HD destruction manual?

Is it still not shifting to fourth! If the the camplate was not twisting off axis, hopefully the pawl carrier tower is OK. Could the pawls or pins be damaged.

As you say a video would help.
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  #40  
Old 13th May 2019
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Yes, The pawls can get damaged I have cracked one when I hit a curb when a nice old lady pulled out in front of me.
After that, the bike would shift up but not down. It turned out the pawl on the ratchet was cracked and bent from over extending when the shifter caught on the curb
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