3rd Gear Skip/Surge

[vej]

Have you checked the shift lever on the transmission itself this happened to me recently i coudnt get past 3rd it would slip in third at high revs and i had no 4,5 or 6th this was the result of two problems first the clutch hub nut came loose and the shift lever on the trans was slipping i did notice when Curtis sent me a knew lever it is stainless instead of alloy like the original this could be a common problem with the alloy levers don't know if anyone else has had a problem with the alloy lever
just a thought

Yep... shift lever checked, had that issue before... this is most defineatly a 3rd gear thing. Once the bike is running again, I'll dig deeper

 

[EMILIO]

Hello here, im from AZ and have a 05 chopper, did we ever find out the issue with this , i have same issue

 

[vej]

Hello here, im from AZ and have a 05 chopper, did we ever find out the issue with this , i have same issue

OK... so, not 100% positive yet, but we are pretty sure we know what the problem is and how it happened (most likely)... I'll get a couple pics together and do a write-up real soon...

 

[vej]

TRANSMISSION ISSUE RESOLVED:
If you look in the service manual, in the transmission blow up. #71 is the Main Gear Assy, but that's all it shows. However, inside of that assembly are 2 HK2520 needle bears and a seal. Funny how the manual doesn't point them out in any way. The first tech at Baker didn't either. It was Mark at Baker that gave me the part numbers (The whole gear assy is $220, the bearings are $10 each). Anyway, the outside set of needle bearings were destroyed. Looks like some where damanged or flattened and they just slowly ate themselves up. This seems to have possibly "slightly" put some odd stress on the shift forks, because the fork nearest the bearings had the pads slighty wore off and a light groove into it.

Replaced all 3 shiftforks, the 2 pressed in needle bearings and the seal.... shifts wonderfully... all 6 gears are back.

See Attached pics

 

[EMILIO]

ok 2 more questions, so you replaced the main gear assy, 3 shift forks, 2 each needle bearings, seal, what was your total cost?
And where you able to remove the transmission door assy without removing the transmission from the bike or removing primary from the tranny? im about to attempt this job so this info is very helpful, thanks so much.

 

[Th3InfamousI]

ok 2 more questions, so you replaced the main gear assy, 3 shift forks, 2 each needle bearings, seal, what was your total cost?
And where you able to remove the transmission door assy without removing the transmission from the bike or removing primary from the tranny? im about to attempt this job so this info is very helpful, thanks so much.

You can remove the door without taking the whole thing out but I wouldn't recommend it. The rebuild is a lot easier out and it's not a lot of effort. Also while your in there replace the bearing on the clutch side too along with the seal.

A little hint the case is known to crack don't use a shop press you'll regret it. Get the right tool for the job. A Harley transmission bearing puller and install tool. Part #34902.

You can get a rebuild kit for about $300 includes bearings, seals gaskets. Shift forks are separate. Check out www.wildsteedworx.com he's got all the parts and prices listed

Sent from my 831C using Tapatalk

 

[vej]

ok 2 more questions, so you replaced the main gear assy, 3 shift forks, 2 each needle bearings, seal, what was your total cost?
And where you able to remove the transmission door assy without removing the transmission from the bike or removing primary from the tranny? im about to attempt this job so this info is very helpful, thanks so much.

I didn't have to replace the main gear assy... just the 2 needle bearings in the assy. They are about $10 each, and maybe $8 for the seal. Each shift fork is $44. New trap door gasket, a couple more $$ ... I didn't have to take it out of the bike, but you do need to take off the top, exhaust, etc... very simple and straight forward. Shifts wonderfully now... all for maybe $150