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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #1  
Old 4 Weeks Ago
bobber58 bobber58 is offline
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Default Transmission issues

whew I'm whipped. Just went from a bare frame and bare set of flywheels to a complete running bike in 3 days. Went to go for a ride, and I cant get 2nd gear. Now I knew there was a potential issue when I put it together, so Im not completely surprised. The issue is that I can't get countershaft 3rd close enough to countershaft 2nd to engage it when running. It an Andrews gear, and I used a +.020 shift fork, but my spacing is still like .085 between the gears. This also has me using 3 shims on the inside side of countershaft low to get it far enough away from countershaft 3rd. Theres no thrust washer in there and end play is right at .012. This isnt right, but I gave it a try because well, quite frankly, I can't find any shift forks longer than +.020. Anybody ever deal with this or have a solution?
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  #2  
Old 4 Weeks Ago
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Default

I think 0.085 is way too much space - you should recheck the spec in the FSM. Mine says 0.028 - 0.058, but that's for 79+ and I don't know if it's the same in earlier models.

Sounds to me like you need to reduce the space between CS 2nd and 3rd, then reduce the space between CS 3rd and 1st to match, and take up the rest of the end play with a thrust washer. Double-check you're moving CS 3rd the correct direction with your +.020 shift fork. Also check if there are any shims between the shift tower and trapdoor.
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Old 4 Weeks Ago
bobber58 bobber58 is offline
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Yes, thats exactally what i said I needed to do, but from what I see, they don't make the parts to do it.
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  #4  
Old 4 Weeks Ago
needspeed needspeed is offline
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Default

Are you positive you're using a +.020 fork? On used forks sometimes the markings get worn off. At .085 spacing you need at least another .020 (a +.040 fork) and that would still only bring you to the high end of the spacing spec. You should never need a fork that long. Something is definitely not right.

Good question about if there are shims betwee the door and shift tower.

Check your fork measurement against the std fork in this post.
A +.020 should measure 1.176.

http://xlforum.net/forums/showpost.p...2&postcount=20
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Default

your 20t gears aren't on the wrong shafts, are they? cs should have four slots on the back, and ms should have five. that would prevent the trans from moving into 2nd, don't ask me how i know that one! i don't recall now if those two gears are the same thickness or not. could be the opposite too, i seem to recall both sliding gears have the same inside spline count and could potentially get mixed up. also check that the shift forks arent butting into themselves on the shaft.
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Old 4 Weeks Ago
bobber58 bobber58 is offline
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Default

My fork is a brand new +.020, verified with a caliper and compared to a factory fork. And mainshaft spacing is right on the money. Countershaft 4th and 2nd line up really nice too with the clutch gear and mainshaft 3rd. Its just something that seems to be going on with countershaft 3rd.
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