clunk from primary or drive train like a tooth jumping?

[Nomad2day]

Last week one day while cruising at a steady rpm 2-3K, the bike lurched like the primary chain bind-ed or jumped or the rear drive belt jumped a tooth. Thought maybe the clutch slipped for a second and then grabbed too. I did put some pipes on and adjusted the clutch, grease the ramp and rod in case it was the clutch adjustment. The clutch starts to grab pretty close just after you start to let the handle out. I had a wrench on the primary nut and checked the clutch basket nut then too, to insure it was tight.
Anyway, yesterday I took it out and it did the same thing again a few times. Feels like if you were peddling a bike the chain jumps a tooth or two.
The final drive belt does need to be replaced due to a couple of gashes on the top side but none of the teeth are damaged. I tighten the belt up some anyway. I opened the primary inspection cover and adjusted the chain tension up some. Maybe a little loose but seemed pretty good. Took it back out and it jumped some more.
What do you think I need to revisit and check. Does not do it under acceleration but while under a steady RPM, 3 k anyway.
I am going to open the primary cover again and see if the primary drive nut came loose and the compensator is loose.
Any Other suggestions?
Thanks in advance for any direction,
Neil

 

[narow37]

Trans is the only thing left in the drivetrain that you didn't say anything about. not sure.

 

[Rottie]

Nomad, You said there where gashes on the top of the belt? It sounds like it is doing the same thing my 06 chopper did when I broke the pivot bolt. The swingarm would move to the side and the drive belt would slip, leaving gash on top of the belt. The dealer at Mytle tighten the belt and it kept doing the same thing! He finally found that the pivot bolt was snapped in half. Just some thine to think about!

 

[V]

Good point by Rottie. Also no chance of a miss or ignition stumble

 

[whatever01]

Check the pivot bolt as mentioned earlier. Look at the rear of the bike with it on the kickstand and see if the wheel looks out of allignment with the fender and struts, you may notice it is offset to one side. Just a thought.

 

[bdmridgeback]

No compensator on bikes 2005 and newer, so that eliminates that. I would agree, that you may want to look into the drive belt/swingarm pivots.

 

[Nomad2day]

What can I say...Thanks for all the awesome advice.
I will definitely look at the pivot bolts. My new front tire came in today so I had it mounted on the rim. Could not find my Dyna Beads so that sux's big time. Got the front tire mounted. Started to look at the pivot bolts but it seems somewhat involved so I will hold off until tomorrow on that. Threw a ratchet on the pivot socket head cap screws and they are tight but will go through it tomorrow.
Any pointers on how to check them out?
Thanks again,
Neil

 

[Nomad2day]

The manual goes into a lot of detail to remove the swing-arm. Do I need to do all of this or is there something to check without removing the swing-arm.
Remove the caliper, rear fender, belt guard, exhaust system, and rear wheel. Disconnect the oil line and remove the oil tank. Remove the shocks and then remove the pivot shaft screws, pivot axle and swing-arm. Note the locations of the pivot spacers...
Do I need to do all this to check it out?
Looks like fun anyway..
Neil

 

[BBChopper]

Bro I hope ya get it worked out!!!
Pivot bolt sounds right??

 

[Vegas]

Broken gear in the primary or tranny. Does it do it in all gears or just one?

 

[Nomad2day]

Broken gear in the primary or tranny. Does it do it in all gears or just one?

Does it in 3rd gear Vegas I know. Happens about 2500 rpms. I thought maybe in 4th,5th too but not sure now...Not all the time but more of late.
Belt does have cuts on the top in a couple of places. I originally thought it was from picking up rocks but now I am not so sure. Winter has come in here so I will pull it down and look into the pivot area. I am going to eliminate the EHC while I am at it
Of course I will open up the primary and check there first. I will do that Sunday for sure. Too much family stuff going on today.
I have had a lot of vibration lately but thought it to be the worn out front tire. I have replaced it now and took it for a short spin and it is better. It jumped in third gear today. I tried cruising in 4th to see if it would do it but it did not. Did not go far due to it has been raining and 40 degrees.
Neil

 

[Nomad2day]

Pulled the swing arm out today. No broke pivot bolts but something. The manual calls for a long pivot bolt and a short pivot bolt. Both of mine are the same length if that means anything.
When I checked the spherical bearings in the swingarm for excessive play I found the belt side frozen pretty much. Had to put a ratchet through it to rotate it at all. Book says to check for excessive play, binding or any restriction of free movement.
Guess I need to contact wicked bastards to order a couple and the retaining clips.
The clutch adjustment rod which I lubed with Mobile 1 grease when I installed it has numerous scars in in it and scraps...
I do not see where this correlates with the clunk in 3rd gear but can see where it may be a issue with the belt being scarred up. I will continue to drain the fluids and yet to look in the primary.
Thinking if I should pull the tranny and send it to Baker to look into it and see if something is going on. The clutch basket nut has loosen once before causing me to lose the clutch on the way home once.

 

[Gas Man]

Neil, I replaced my swingarm bushings on my chop last winter. Really easy job. I found the same thing.. one of them froze up. Maybe that is all the problem is for you.

 

[Nomad2day]

Neil, I replaced my swingarm bushings on my chop last winter. Really easy job. I found the same thing.. one of them froze up. Maybe that is all the problem is for you.

Thanks Gas,
I knocked the one out per the manual and destroyed the clip due to it not wanting to spread out on one side so I could remove it before tapping the bearing out.
It would be nice if that is all it amounted too but I think it would feel like it is jumping teeth or the clutch was slipping in all the gears, just not 3rd gear so far.
Neil

 

[Vegas]

I was hoping to catch you before tear down. If it's only one gear then it eliminates everything else. If it was a belt...it should be under high load or full throttle.

 

[Nomad2day]

Vegas,
If I understand your comment, the problem is in the transmission. Seeing how it happens in 3rd only and at cruising speeds it seem the shift fork or bearing is no longer under load allowing the transmission gears or shafts to float and fall out of 3rd. Under acceleration or a load everything stays in place. Could of a keeper clip come out? Do not know much about transmissions but looking at the power flow looks like something on the counter shaft is not holding...
I am going to read some of the transmission threads and see if I can get a understanding of some of the troubles they have had.
Neil

 

[Vegas]

Definitely not an expert on manual trannies. I haven't had one apart since auto school and that was about a bud light truck ago. :roll: I think it's going to end up being a synchro. I would make a call to baker.

 

[Gas Man]

Neil, I used a large socket to pound mine in and out.

 

[Nomad2day]

Opened up the primary and got the clutch pack removed as well as the primary gear and this is what I have found. It also makes me ask a question on backlash or free play in the transmission main shaft.

Anyway,
I found two chunks of metal on the magnetic drain cap and 3 places on the inner primary where the bolts on the backside of the clutch pack have hit it. This could be the clunk I have experienced where the bolt head hits the case and then goes by the open slot and then hits the case again causing the primary chain to jump, tighten or be it, slack from the backlash tightening up again and popping the chain as it grabs again. Why it is hitting I hope someone can direct me to the answer.

Here is the 2 pieces of metal that was on the magnet. Not sure if it is the casing that was scooped up or what.

 

[Nomad2day]

Here is the amount of backlash that I was talking about. I am reaching around holding the final drive pulley on the other side of the transmission to feel when the gears engage. It is the same in all the gears, well 2nd and 3rd anyway. It is pointing at the top mounting hole when it starts and moves about a 1/8th of a complete rotation before the slack in the gear is gone.
It seems the chain stops spining for a second until all the slack is gone and then, blam, the noise or clunk I said I was hearing.