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  #21  
Old 3 Weeks Ago
Iron Mike Iron Mike is offline
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Sportster/Buell Model: xlch
Sportster/Buell Year: 1964
Sportster/Buell Model #2: XLCH IR EFI
Sportster/Buell Year #2: 1971
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Other Motorcycle Year: 2001
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Thanks for clearing that up. Trans must be good 1st-3rd! Slap her in there!
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  #22  
Old 3 Weeks Ago
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MonkeyMadness MonkeyMadness is offline
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Posts: 222
Sportster/Buell Model: XLCR "Blacky"
Sportster/Buell Year: 1977
Sportster/Buell Model #2: XLH Bobber "SmokyBitch"
Sportster/Buell Year #2: 1976
Other Motorcycle Model: Sold 883R / 1425
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Okay so i got everything pulled out. It looks like its a issue with a few things. Tops hat is worn. Front leading edge of the dog teeth on the intermediate gear that engages while in first has excessive wear compared to the rest.
But what worries me is that the case is warn wear the intermediate shaft and roller bearings are. I can see where the gear has been riding the case and warn a grove into the case.
What's odd to me is that the thrust washer for the gear and shaft are thiner that valley the it rides in.

All 3 of these allowed the intermediate gear to jump out of engagement while under load.
Now my main concern is this wear on the case. What do i do about that? Can / do i shim the shaft?
I have another trans mission I'm going to use and i noticed just like the one i pulled out the thrust washer is thinner than the valley is rides in. And surprisingly this trans look as if it's has almost no wear.
All highway miles granny said
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  #23  
Old 3 Weeks Ago
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doodah man doodah man is offline
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Location: 37° 25' 28" N by -80° 03' 42" W
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Sportster/Buell Model: XLCH
Sportster/Buell Year: 1975
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Counter shaft 1st gear on mine is the same - the thrust washer sits a little below flush. It’s not a problem as long as the end play was measured correctly. Did you measure the end play before removing the transmission like ezmerf mentioned? That would be good info to have. End play is all that particular thrust washer controls. As far as the wear is concerned, it’s hard to give any advice on that without a pic. There are a few threads around here about measuring gear spacing and endplay. How does the cam plate look? Are the “sharp points” mashed or rounded? If your “top hats” have wear then the cam plate probably does too.
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  #24  
Old 3 Weeks Ago
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Location: 37° 25' 28" N by -80° 03' 42" W
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Here’s some good reading
http://xlforum.net/forums/showthread.php?t=1734747
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