Shifting issues. Shifter lever assembly play(video)

[Josh662234]

Any Buell Gurus within 500 miles of me? I'm in Mass

 

[vance580]

It will have play without the other side of the case not attached. If the other side isn't on it won't shift through gears at all or maybe just once. There is force and moment that has to be picked up by the other side of the case to make the transmission work correctly. The only thing I see wrong is that one shift shaft. If you have it mounted it should not be that lose. Once you rubber mallet it into place you should have to use the holes on the primary side to get it back out. Too bad you weren't closer to me I'd give you a hand reassembling.

 

[Josh662234]

Once you rubber mallet it into place you should have to use the holes on the primary side to get it back out

I figured this was the case, but I can put it in and take it out, no rubber mallet required :/

 

[vance580]

Yea that may or may not give you problems. If it was me I'd just reassemble and hope for the best. If it a problem the case mount is done and you will have to get a new case half so you might as well just hope for the best and reassemble. It may not be enough play to affect shifting. When you reassemble the shifting will be a little tight at first till you get some fluid going through there. Took about a day of riding for mine to go back to normal.

 

[Josh662234]

went into work today to use a socket or two that i didnt want to pay a pretty penny for

For all those who are wondering, the front drive sprocket is 1 7/8". i couldnt seem to get a straight answer here using search. (Bike is a 2007) Here is how to get it off, if you forgot to take it off before dissasembly, like me

Im going to try and put the cases together (dry) tuesday when i can get the help seeing how im in a cast, and i'll see if it shifts through all the gears. i'll be honest, i'm a little skeptical

 

[Josh662234]

This might be a dumb question /\
let me know . . . i'm slowly losing hope

 

[thrstrmech]

did you look at the bearing on the left hand case cover that the shift cam rides in? also the bushing on the right hand side case? could be worn giving you the play and the shifting shouldn't be like that...I'll read up on the installation portion of these components, and if there was something misaligned

 

[vance580]

Did you push the springed pin thats mounted in the pulley side of the case? If you didn't pull out the neutral switch and make sure that was moved when putting the cases together you may of mashed it on the back side of the shift cam which would bind it up.

 

[Josh662234]

did you look at the bearing on the left hand case cover that the shift cam rides in?

Yes i did and now with the cases together the shift drum is nice and tight

Did you push the springed pin thats mounted in the pulley side of the case? 

yes and it is operating properly

 

[thrstrmech]

ok, bought the sockets needed to remove the nuts...so the transmission sprocket nut is loosened to the right as well as the clutch pack? main drive to the left as normal, correct? got it into 1st gear, tried going into the others, but not sure if I can get it into 5th and hold the rear brake to loosen the transmission sprocket nut...following what squidebuellie suggested on how to do it

 

[thrstrmech]

hear nothing but crickets

 

[vance580]

I didn't take the sprocket nut off so I'm sorry I can't help. You don't need to take it off to split the cases if that's what you are doing. Unless you are replacing the gear in the transmission for it you can leave it. I used needle nose pliers to get the neutral safety switch out too so didn't need to remove it for room for that either.

 

[thrstrmech]

not sure if the transmission gear is damaged, think it may be the shift fork(s) that's causing the problem, but want to get it off just in case that is part of the problem...was your issue the forks?

 

[vance580]

Yep mine was pretty much the same as the OP except my shift cam was also damaged. Unless you had a catastrophic failure that one gear is most likely fine. The rest of the gears will be on the other side of the case and those are typically the ones that would have damage if any.

 

[thrstrmech]

cool, at this point think I'll leave it as is and proceed with removing the engine from the frame and get her split, thanks

 

[Josh662234]

It lives!!!!!! Not only does it start, but it
Shifts!!!!!!!! I must say I am quite proud of myself. I was not going to let the rain stop me from finding out if it was fixed or not.
Had a **** eating grin on my face all night. thanks to all those who helped, could not have done it without you guys [up]

 

[vance580]

Awesome job. Glad you got it back together.

 

[thrstrmech]

[up], my shift forks weren't nearly as bad as yours, minor in comparison