Transmission lockup!

[bigflash1]

Well, I've had an interesting evening. Took off from the house on the Bolt. Got about one mile from the house, big left hand sweeping turn on the highway, my transmission LOCKS up! Back tire locks, big skid, highside smack...! cops, ambulance, the whole enchilada...
Had to cut my drive belt to get it loaded on a trailer. Back tire would not move. It will run with the clutch pulled in, but won't move the trans. Won't shift, just locked up tight. I rode the thing all weekend in Daytona, rode back to Savannah on the highway doing 70+... can only imagine if it would have happened going that fast vrs 55ish.

Lots of asphalt rash, possible broken wrist, hurt motorcycle... Sure glad I wear a helmet 100%. I hit pretty hard on my head!

Any ideas on what might have caused the lockup? I changed the oil in it less that 1K ago with real HD trans oil. It's been 100% solid since I've owned it, about 2k miles /3 months. No issues...

 

[07Bolt]

sounds like maybe a bearing seized up? or ur clutch took a crap. might be the engine sprocket nut crapped out and locked up the primary; but stills allows you to start it with the clutch dis-engaged. take off the primary cover and have a look see.

 

[jetlee]

Dude...same thing happened to me a few years back! I did bouncing backflips after the bike pitched me over.

Cause of mine was a trashed chain tensioner, I determined. I dunno if it was a piece of the tensioner or the spring or what that got locked up. I was able to ride it home though (after hard rocking it back and forth for a couple minutes, it came free), with the primary rattling like mad. Drove myself to the ER in the car when I got home. I was bruised badly, but nothing broken.

Ended up replacing the tensioner, spring and chain.

 

[twobuells]

It sounds like the problem several have had. Usually on 03 to o5 bikes. It probably has a bent shift fork causing two gears trying to be driven at the same time.

 

[bigflash1]

That sounds like what I've possible got. The shifter is definitely not working at this point.And it's an 05...

Thanks

 

[bigflash1]

Hello ladies and gentlemen!

I've managed to get into the guts of my bike. Here's what I've found. I was LUCKY and found a complete transmission on ebay, and got it delivered to the door for about $200. It's going back together slowly now.
1st time I've been into a Harley type bike, wow was it way easier than dealing with Japanese makes.
Was able to build or work around most of the "Special" tools requirements. The most complicated was the tool / setup to press the trans back together. We used oak blocks with holes and it went back together without any problem.

Looks like this was the cause, bent / broken shift fork.

 

[firefighter1c57]

I really can't tell, is that third gear? So the shift fork wasn't fully engaging the gear and the teeth couldn't take the half load?

 

[EricZ]

Now that is impressive!! Glad you're ok!

 

[GAXB9R]

That sucks hope you get it together soon.

 

[bigflash1]

Firefighter1c57 - I think it's actually 2nd gear (both main and countershaft)that exploded. I'm not sure exactly, but think I tried to shift up (was doing 55 or better) and felt like a missed shift. Tried again and locked up completely.

I've got the cases back together now. Takes longer to clean and prep than to assemble.

I've got some spare trans pieces now. Anyone looking for anything specific?

 

[jgcable]

Glad everything is ok. Can you explain exactly how you pressed the main and countershafts into the engine case? I am doing the exact same thing on my 2003 for the exact same reason as you. My pictures of my gears and shifter forks look exactly like yours. Mine locked up downshifting from high way speeds. Hit 2nd gear and it locked up tight.

 

[bigflash1]

We just stacked up some hardwood squares, drilled clearance holes in them and set it all up on the press so the main and countershaft were at about the right height to press back into the left case. I don't know how different the 03's are than the 05's so... It was just really using what we had at hand.
It was sort of a poor mans version of the trans tool that is pictured in the shop manual. We just pushed a little on each bearing race a little at a time until they seated. Biggest thing was to get the wood blocks about the right height to hold the two shafts upright at the correct height. Wish I had taken some pictures. Should have. You really have to set the assemblies up like that as the gears try to fall / shift and the last one has a bushing on it that gets whacky and won't let things press into place.

 

[flaya564]

You'll got me worried now. I have an 03 XB9S.
Are there any warning signs or things that come to mind after the fact?

I'm gonna be riding two up this season, for the first time and I would hate to launch my girlfriend off the bike.

Anyway of check for issues?

Thank for any help.

 

[bigflash1]

Mine was sort of "Fuzzy" on shifting at times just prior. Sort of like it was trying to get into gear, but not quite making it. It did it 2-3 times before the transmission / bike crash. All I can say is if your system isn't feeling right, don't force it or bad things may happen. It's a relatively cheap fix if you don't break anything if you just have to put in a shift fork or two and gaskets.
I "Think" I may have stabbed at my shifter when it did this to me trying to shift after possible fork break... Hard to tell exactly what really happened. You just don't think about shifting. It just happens.

I don't think this is a huge issue? Is it? There are some other folks with trans issues, but this is the 1st I've heard of a total lockup. And my 1st for sure in better than 40 years of riding. Harleys are pretty rugged systems.

It did re-enforce the need for safety gear. I do ride 110% with a full faced helmet and gloves. I was however only wearing a t-shirt / jeans and I did pay for that!
I saw a couple out this weekend, both wearing shorts, sleeveless shirts, and flipflops...!

 

[bigflash1]

Well, My Bolt is all back together. Took her for a ride this afternoon and she's healthy again!
Without this forum, I'd have written it off as a loss and gone on to another.

Things I did right:
1. Jumped into the repair without a clue. Wasn't that difficult at all. Just follow the manual for sure.
2. Changed to the vented engine arrangement outlined in the threads on the forum here.
3. Had Randy rework my pipe. (Randy, it rocks!)
4. Wired a heavy duty feeder for my headlight to handle the amp load of the xenons.
5. Added bar end weights to my handle bars (Helps allot with the vibration as well as the gel grips)
6. Changed to the 1" offset pegs
Things I didn't do but wish I had now:
1. Changed to the bronze oilpump driving gear, didn't find out about that until after I have the engine back into the bike.
2. Wrap my exhaust pipe while it was off the engine (it's 95 deg here today. My right leg is toasty.

For anyone who is contemplating fixing or forgetting their bike because of a blown trans, I can only say go for it. It's not that hard to fix, and you will learn allot in the process. Take good notes, take a few pictures, and follow that shop manual.

Thanks again all, for all the help!

 

[user_deleted]

bigflash: i admire you for even tearing into that trans and sorry to hear about your crash...hoping you're on the mend and healing well. just curious...how hard has this bike been ridden? missed shifts? abused? not being accusatory here in the least but wondering its history cause these transmissions are fairly rugged. thanks much.

 

[bigflash1]

Not sure about it's past, and I'd only had it for 3 months prior to this. I don't pound on it.
Pretty sure it was just a mechanical failure in this case. It does have 17k miles.