MOTORCYCLES247
Well-known member
My 2004 XB12R had the transmission get stuck in between going from 2nd to third. Would not go up or down to make a gear change and this is what I found out and what I did to fix the problem. For All 2003 2004 and 2005 XB's all had an ALL Aluminum Shift Cam or Drum and there lies the problem because 2nd to 3rd gear track in the Shift Cam mushrooms over on the High Point in that Cam grove and makes the Shift Fork roller bind badly. The High Point rounds over into the shift fork track which is now to narrow for the shift fork roller to pass freely. In 2006 Buell trans was completely changed except shift fork guides and 1 primary side Main Shaft bearing. The Ugly part of all of that is the Engine Cases were Redesigned to fit the other 3 Bearings that are a different size than on 03-05. I knew I could get a brand new shift cam from HD but why use something that eventually will do the same thing an not from abuse or improper lubrication plus it was $315.00. When I first posted about my trouble I received info from 34nineteen and Cooter and they put me on the right path. Was able to find and get 2006 Engine Case for $75.00 and a 2007 transmission for $150.00 on E BAY-YEA.
Several things I did which will help things go good are
1. Made a wood support frame to hold the rear up to make the tire and rear sawing arm and rear shock removal a breeze.
2.Only pulled pistons out of the cylinders from the bottom enough to remove wrist pin clip so rings and pistons stay in the bottom of the cylinder.
3.Double check Oil Pump Drive Gear on the Crank or just replace it with the 2006 and newer up grade gear. Mine was paper thin on 3 of the teeth.
4.OEM all torque spec's on all engine bolts or if you get Cometic gaskets use there spec's for head bolt sequence and torque range.
I did have to buy a new Main Output shaft bearing that did not come with the used cases and that bearing was $53.00 from HD. I have about 2,600 miles on it in a little over a month and is 100% no leaks and shifts good. I will say the Newer style Helical cut gears over the straight cut like higher RPM's when shifting. I know I would do it again but I think I will just Upgrade to the THUNDERSTORM ENGINE in the future.
Several things I did which will help things go good are
1. Made a wood support frame to hold the rear up to make the tire and rear sawing arm and rear shock removal a breeze.
2.Only pulled pistons out of the cylinders from the bottom enough to remove wrist pin clip so rings and pistons stay in the bottom of the cylinder.
3.Double check Oil Pump Drive Gear on the Crank or just replace it with the 2006 and newer up grade gear. Mine was paper thin on 3 of the teeth.
4.OEM all torque spec's on all engine bolts or if you get Cometic gaskets use there spec's for head bolt sequence and torque range.
I did have to buy a new Main Output shaft bearing that did not come with the used cases and that bearing was $53.00 from HD. I have about 2,600 miles on it in a little over a month and is 100% no leaks and shifts good. I will say the Newer style Helical cut gears over the straight cut like higher RPM's when shifting. I know I would do it again but I think I will just Upgrade to the THUNDERSTORM ENGINE in the future.
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