Rebuild Observations...

[jgcable]

I have been riding for years. Tons of different bikes. I wrench all my own bikes. If I can't figure something out I can always depend on a forum or a good service manual. Not with this 2003 XB9R.
What a friggin nightmare. No wonder I got it so cheap. Its literally a media blackout when it comes to the complete teardown of one of these motors.
I guess when the transmissions goes on one of these bikes you just junk the motor and get a new one.
I feel like Indiana Jones exploring the Buell Mystery when it comes to a motor tear down. Just needed to rant a little. Stupid transmission fork drum installation is screwing up my entire riding season.
Bummer. Are there any Buell owners on this forum that have done more than cosmetics on their bikes?
I would think that guys who track race their bikes must be familiar with teardowns and transmission work. I guess none of them are members of this forum.

 

[netty2424]

You started out asking if anyone has done any repairs other than cosmetic, and ended the same post with no one on this forum has???

There are some great Buell minds on this forum. Just tap the brakes a little brotha and I'm confident those with tranny repair experience will chime in! [up] there are lots of guys here with the knowledge who are more than willing to help!

I myself have not repaired a transmission, otherwise I'd be happy to help! Hold tight! Hope you get it sorted out!

 

[netty2424]

Now I understand your frustration. You already posted on this issue!

Other thread

 

[wolfo68]

Have you not seen my posts?

xopti < you may want to send him a message, he's rebuilt plenty.

 

[07Bolt]

Just tap the brakes a little brotha

cant tap the brakes unless the tranny is working lol

trans work is fairly easy; theres a pic by pic thread somehwere on here about the trans. guy had the whole trans out but ended up with the wrong parts on the trans he ordered. the shafts werent the right sizes or something

 

[netty2424]

Jgcable, EricZ is another forum member that has experience here. I'm sure coupled with xopti, they'll get you sorted out.

 

[Xb12armyguy]

good info here, next time my craps out instead of paying 1000 for a rebuild ill do it myself, i can rebuild anything else so a bike trans cant be to bad!

 

[jgcable]

Thanks for the names. I am surprised after weeks of posting threads about this exact issue I really got no responses from anybody. I will seek these guys out.

 

[jgcable]

I have been in contact with EBR too. They can't help. They told me to contact a dealer. I contacted the dealers in the area. They told me I could bring in the motor and they can see what they can do. $100.00 min bench time. I just need to know what position to install the shift fork drum. It just drops in. I could install it in 2 minutes. I just don't know what position it needs to be in because its round and the 3 shift forks fit into it in just about every position.

 

[wolfo68]

sorry about that man, I've been kind of distant from the site lately trying to finish rebuilding mine.

 

[EricZ]

What shift drum issue are you having? Did you get the main and counter shafts installed in the left side case? Once you do that you can install the shift forks on their grooves, then install the shift drum, and finally rotate the shift forks to engage with the shift drum and install the shift fork shafts. All of this is performed on the left side engine case. Be sure to thread in a tool to the neutral light switch hole to hold back the shift drum detent arm when you try to put the case halves together. If you need any more details I can easily share them with you!

 

[EricZ]

Just read your last post, JG. The main shaft has 2 shift forks, and the counter shaft has one. Look at your shift drum and trace the shift fork grooves. The outer grooves closest to the ends of the shift drum are for the main shaft forks and the groove in the middle of the drum is for the counter shaft fork. The drum orientation almost does not matter when you drop it in. Just rotate it around to allow the forks to fall into their respective grooves. I'll take some pics and post them soon.

 

[oh9bolt]

EricZ is really Erik Buell.

squidbuellie is another member that knows alot about Buell's. PM him.

 

[EricZ]

Does this help?

 

[EricZ]

Did that help?

 

[bigflash1]

Hopefully you have gotten the assy back together. If not, I had the same issue as one of the other guys, in that my trans was locked up in what was left of a gear and there was no way to get it into position prior to dis-assembley.

I laid the assy down on my bench, just the way it would fit into the cases. Then got all my gears into place so I had neutral (None of the dogs were engaged on any of the gears). Then it's fairly obvious how the shift forks go in based on the slots in the gears. Follow the manual to figure out the correct gear for forth, then hold things together and get the 4th gear dogs engaged. Mark the shift drum then in the 6 oclock. Then you should be able to follow the manuals instructions for getting it back together. I used a couple of hardwood blocks and build a sort of temporary assy jig. Look at the manual and think wood vrs steal.
Really though, it was laying it out on the bench and getting everything aligned prior to trying to assemble that made the difference for me.
Hope this helps. Mines an 05 XB12R so it may be somewhat different. This was my 1st time in a Harley transmission/engine. Want trouble? Try wrenching into one of those Japaneses bundles of fun!

 

[jgcable]

Thanks for all the responses. I dropped the fork drum in and put the forks into their respective slots.I then put the case together temperorarily without the crank installed. I used a little screwdriver to shift the drum and it seems to work perfect. One click down and its in first. 1/2 click up and its in neutral. 4 more clicks up through all the gears. The drum appears to be spring loaded because everytime it shifts the fork drum clicks and moves in and out depending on the gear. I still don't understand why they ask to mark the drum prior to dissasembly. It seems to me that it almost doesn't matter what position you put the drum in as long as the shift forks are in the right slots. I had it correct all along I guess. Now I need to find somewhere local to by Dow Corning Silastic 732 Silicone so that I can install the crank and bolt the 2 halfs of the engine together. Not a single local store carrys the stuff. I can buy it online though.

 

[jgcable]

Also, I didn't use a press or a jig to install the main and counter shafts. I made sure they were straight up and down, I supported the underside where the bearing is with a large socket and I tapped them in with a rubber mallet until they were fully seated. The noise changed when they were fully seated. I then installed the fork drum and the forks, let them slip into the grooves and then I installed the fork tubes and tapped them in with a hammer until they were seated I threaded in a large bolt in the neutral light switch hole to keep that arm with the spring on it away from the hole. I put the two halfs together. They went together perfect with no issues. Smooth as silk. I tried the transmission and all the gears work so I guess I got it!

 

[jgcable]

Its coming along! I just ordered a new set of piston rings and a complete engine overhaul gasket set. I also ordered the correct Dow Corning 732 to seal up the engine halves. Once the parts arrive I plan on having the motor done is a week or so. My plan is to install the motor and not install the drive belt until I get the motor running correctly and shifting correctly. Does this sound like a logical thing?

 

[wolfo68]

sounds logical to me