5th Gear Chatter

Energy One
gotplz2

gotplz2

New Owner
I was running through the gears pretty fast the other night on my 05 chopper with 2600 miles. When I went to stop it wouldn't go back into first until pushing down on the shifter a couple times. Since then I hear a chatter in 5th gear. All the other gears I can't hear anything but in 5th gear it chatters at all rpms.

I took off the primary covers to check out the clutchs and the clutch hub nut. Everything looks good. Changed all fluids and put everything back together and still the chatter.

Any suggestions?
 
gotplz2

gotplz2

New Owner
I took the linkage off and the eyelets move fine and don't looked gummed up.

Thanks for the suggestion.
 
B

bigdogtech01

Well-Known Member
gotplz2 said:
I was running through the gears pretty fast the other night on my 05 chopper with 2600 miles. When I went to stop it wouldn't go back into first until pushing down on the shifter a couple times. Since then I hear a chatter in 5th gear. All the other gears I can't hear anything but in 5th gear it chatters at all rpms.

I took off the primary covers to check out the clutchs and the clutch hub nut. Everything looks good. Changed all fluids and put everything back together and still the chatter.

Any suggestions?
Click to expand...
If you were hammering down threw the gears you might have bent a shift fork. You will have to take the top cover off along with the drive pulley in order to slide the shift fork shaft out. With the top cover off you can then remove the shift drum assy. There are 3 forks inside your transmission, Remove all 3 keeping an eye on what one came from what location. Once removed, inspect for wear and if any are bent using a flat plate.
 
gotplz2

gotplz2

New Owner
ok. Thanks! Do you know where there might be any diagrams, pics or videos that might show how to do this?
 
C

Chopper117

Chopper Nutt
I just replaced all 3 forks in mine last week and solved my chatter in 3rd gear. Just like Bigdogtech said take the front pulley off, the top cover off, the shift drum off and I even took the side cover off so I can inspect gears as well. Then I started to slide fork rod out and taking one fork off at a time as I slid the the rod out. Then once I got the forks out I inspected them with a straight edge to see which ones were bent and then I rolled the fork rod on the table to see if it was bent also. My 3rd counter fork was bent and worn so I decided to order all three forks to be safe and also gaskets for top and side covers. I then called Scott at Baker and ordered my stuff and got it in 2 days and had it back together same day. It never shifted so good!
 
C

Chopper117

Chopper Nutt
$112 for forks and a couple of bucks for gaskets. Get a retainer clip that goes over the countershaft bolt cuz i would check that bolt as well and you will destroy it getting it off. I also bought an extra countershaft bolt just in case.
 
gotplz2

gotplz2

New Owner
That's not too bad. Hopefully I can figure it out. Goin to start tearing it apart tonight. I'm goin to try and take pictures and document it so that if anyone else has this problem they will know what to do.
 
gotplz2

gotplz2

New Owner
I took em' out and they don't look bent. There's a small amount if wear on one. But it doesn't seem bad???
 
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Chopper117

Chopper Nutt
gotplz2 said:
I took em' out and they don't look bent. There's a small amount if wear on one. But it doesn't seem bad???
Click to expand...
Did u put a straight edge on them? Mine was only slightly bent but that's all it takes. Make sure u roll your fork rod on table to see if it has any wobble to it. And also I would still check countershaft bolt to make sure its not coming loose.
 
gotplz2

gotplz2

New Owner
Yeah and I had a machinist look at them and he said they weren't bent.
Which one is the countershaft bolt?
 
C

Chopper117

Chopper Nutt
gotplz2 said:
Yeah and I had a machinist look at them and he said they weren't bent.
Which one is the countershaft bolt?
Click to expand...
Once you move the retainer clip that looks like a big round rubber gasket, its right behind that on left side of trans.....shifted Pawl side.
 
phatchopper300

phatchopper300

I just wanta ride
I had my tranny rebuilt due to countershaft issues.Here is what my countershaft bolt did. It came thru the cover. There was a SB 1090 that the former owner did not do for 06' models.



Bigdogtech1 did the work and he is great and knows these bikes!!
 
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bigdogtech01

Well-Known Member
gotplz2 said:
What all do you have to take off to get to the bolt? Clutch hub nut? Primary?
Click to expand...
Yes and Yes. Your whole Primary assy has to come off. Once inner primary is removed, you will be able to see what the other guys are talking about. Check your bearings while your that far. Any movement up and down, side to side on the main shaft, either end.. you will need a transmission rebuild. I have seen some fail with as few as 2500 miles, and as many as 20k miles. A lot depends on how you ride. If your riding it hard all the time, you will wear the bearings faster. What year is your bike? Transmission has a number on it...whats the number? It's printed on the same side as your drive pulley.
 
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