2009 XB12R Shifting Problem HELP

[Maximumproductsca]

Hey I am brand new to this forum and I really need some help. I bought a 2009 Buell XB12R with a broken shifting drum something came off in the case broke the drum and kind of messed up the whole case. I pulled the motor and cracked open the transmission and replaced the shifting drum. The transmission looked perfect no signs of any issues I reassembled. I also replaced the Clutch basket due to damage from the previous issue with one i bought off of eBay for a 2007 Buell XB12r. After I put the motor back in and put it all together I went for a test run and shifted through all the gears no problem. Then I was on my way back and the shifter got stuck. I went home put it on my lift and removed the Primary cover and saw metal shavings in the primary oil. I looked at the front of the primary cover and it looks like for some reason the clutch basket is moving under torque or something and causing it to hit the case. I hate to tear it all the way down and replace the case but maybe I just didnt put the clutch basket and everything together right..... On another note. Before i took off the primary cover I removed the shifter assembly on the outside of the case and put a pair of vice grips on the shaft and could go through all the gears no problem that leads me to believe something is not assembled right inside the primary case. The primary case does have some damage but nothing that would affect driveability. Please help I dont know what to do.

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[Maximumproductsca]

The pic above was from previous damage to the case but it shouldnt affect rideablitlity

 

[Chicknstripn]

Are you sure a 2007 clutch basket is compatible with a 2009 engine?
If so, are you sure the 2007 clutch basket you got was structurally sound?
If it is, are you sure you installed everything correctly? Are all the thrust washers in place and facing the correct way? There's one that needs to have the word "out" facing towards you. Are you positive that the clutch plates are installed correctly? The shift shaft, with the little spring loaded butterflies that engage the shift drum, may have popped out of place. Have you checked that?
I'm not questioning your mechanical abilities, to split the cases is a huge under taking on these motors, so I believe you know what you're doing. It just sounds like something inside that primary cover is out of whack. I'd start by opening that cover up and disassembling the clutch to insure everything looks exactly as what is pictured in the service manual.
Good luck man!

 

[Chicknstripn]

BTW the metal shaving you mentioned in your oil, you have any idea where they came from?

 

[Maximumproductsca]

The metal shavings in the primary oil are from the clutch basket rubbing on the primary cover.... it just seems like its just like an 8th of an inch too close to the primary cover. do you see in the picture i posted the part off the case where the shaft comes through? the case is broken right there and missing a snap ring. My buddy thinks that maybe missing that snap ring is causing that shaft to shift. I am not sure whats going on.
I am not really that familar with how these bikes shift. are they diffcult/ hard to shift? I am able to put vice grips on the shifter assembly rod and shift the bike no problem but as soon as i put the lever back on the rod it is hard to shift again. my shifter lever is worn and wobbly but I dont see how that could make such a big difference.

 

[Chicknstripn]

I saw the damage in that pic. I also noticed the lack of a snap ring but thought that maybe the 2009 was a little different than the 2007. 2007 firebolt is what I have all my experience with. I definitely think that missing that snap ring is the problem. If that bearing is able to float it's probably throwing the whole drivetrain out of whack. To confirm this hypothesis send the guys at EBR an email with the same pic you posted here. Make sure you mention the lack of a snap ring on the crank bearing and ask if this is what's causing your clutch to go out of whack. You would think the insane amount of torque that is required on the crank bolt would be enough to hold everything in place, however, the motor was engineered with that snap ring in place for a reason. The EBR guys will be the ones to tell you for sure if that's you're issue.
Good luck

 

[Chicknstripn]

Oh my bad. I meant the transmission main shaft and associated bearing not the crank bearing. There really is nothing but that snap ring holding that whole main shaft assembly in place. Without that snap ring the whole main shaft is able to move around. It doesn't take much to throw a transmission out of whack. Sorry I confused the two for a second. The main shaft bearing has nothing but that snap ring holding it in place. I think the amount of material your missing there is exactly what's throwing everything off. Sorry if I confused you talking all that talk about the crank. I got mixed up in what exactly I was looking at.
AND yes. Buell are some what difficult to shift. Especially if the bike is sitting still.

 

[Maximumproductsca]

Thanks.... I tried calling Harley Davidson for a new crack case but they said its obsolete. I called my local dealer as well as harley corp. they said I'm outta luck. I can't find any on eBay and I'm wondering if there is a way to fix that case without removing the engine. Maybe if I could weld a lip and put a new snap ring in ?? What do you think. I know I can't weld steel to aluminum so that's all I can come up with. I don't want to take it out of If I can get by for a few months until I find all the parts I need. How do you think I could fix that lip? Do you think they could weld the aluminum in place at a machine shop? Or welding outfit? I love my buell and I can't see letting her go over this.

 

[Chicknstripn]

I currently have my cases split. I'll measure the amount of material that you're suppose to have there for the main shaft bearing. That way whatever weld shop, machine shop or combination there of, you take it to will have a better idea of what they need to do.
Unfortunately you'll probably have to split your cases again to do the job right.
I'll measure the height at the out diameter of the bearing race(if you can call it that). And I'll try and give you a measurement of where the snap ring goes.
I think a skilled welder can fix the case. Then you'll need a skilled machinist to clean everything up and put a groove on the I side diameter of that bearing area.
Start searching....

 

[Maximumproductsca]

Hey I made quite a bit of headway I tore my bike all the way down and split my cases last night! So if you have those measurements that would be cool! Unless you know someone of if someone on this forum has a crank case for sale? Any ideas? 2007+ Crank Case should fit[

 

[Chicknstripn]

If your bikes a 2008 I think you'll need a 2008 and up crank case. 2007 and earlier models have a smaller diameter crank pin.
I'll post those measurements tomorrow. I didn't get a chance to touch anything in the garage today. Got home from work at 8am and have been going pretty much non stop since. I may it may not have slept for an hour or so. It's all a blur

 

[Chicknstripn]

So here's what I got off my 2007 case. The approximate depth/height of that hole where the bearing seats is .8645 inches. That's from the bottom of the hole to the top. The width of the lip that you are missing is approximately .24 inches. The slot for the retaining ring sits pretty much directly on top of the bearing. The retaining ring is tapered so whatever machine shop you get to take on this task should be able to make the slot for that ring as long as you have one for them to take measurements off of. At least that's how simple I think it should be. But I really have no idea.
Good luck