Won't up shift

[Buell friend]

Ok so I am helping a semi mechanically inclined friend with his buell. I generally work on HD so I'm a little lost. He laid his 03 xb9 down on the left side and tore up the shift lever. I had to machine and weld in a plug where the lever bolts into the primary cover. Once all back together I can shift the bike into first and back to N but that's it. No up shifting. I did some searching on here I took the primary case off and checked for a bent shift rod but it seems good and the bike still won't up shift . Ideas?

 

[Buell friend]

It appears to have the springs and It appears to be correct behind the clutch pack. I'm thinking bent shift forks or a jammed shift drum?

 

[Buell friend]

Here is a picture of where I repaired the Primary cover. Basically milled out a hole then installed a tapped plug and welded it in. Second time I have done this to this particular bike as friends keep buying it as a first bike.

I tried to shift it with the cover off the bike but still no go. I can see the springs but cant really tell if anything is bend behind the clutch.

 

[Buell friend]

any ideas?

 

[jimijeans]

Welcome to the Forum. Sounds like maybe the Shifter drum has some damage or possibly the Fork assembly shifter might have gotten Jammed /bent etc..Not sure because that is something that usually you need to be there to check and feel out.
That said try this WHILE in Neutral .PLEASE be safe trying this. With Primary cover off lift up the Shifter Lever Assembly slightly and you might want to get help if you so need to help with this.ONLY while the ENGINE is NOT Running !!
Then try to feel it out when you try to upshift. Lever in Push in to first if possible.
A Pitt Stand would really be helpfull so someone can try to roll the back tire while testing this area.You can also pay close attention to if you hear noises like a piece of metal bumping around inside the Gear Box area while trying to roll the Wheel back and forth.
Usually when the Shifter won't shift something inside the Case is bent OR other damage has occured inside the Transmission and reQuires going in to the Case.It is possible that the Shifter Rod got bent or [jammed ]usually meaning it is bent.
The Shifter Drum also has 5/pins or Roll pins at the end and could be bent. That is a touchy one so make sure to be through so as not to damage other parts that are still good.
IF I was doing that job here in the Shop' I would check all outer parts up to the outer areas and after that Remove the Engine and get ready for inspection on the inner Transmission.Take your time. There are manuals to check out here on the Forum. Good Luck. *Jimi