Hard Shifting after warming up!

Energy One

Bodie

Member
I need a little knowledge. Any help would be appreciated. Little back story first....bought an 03 Chopper several years back and thought I got a "good deal". Not so much! Right out of the gate I had to have the stator replaced at a local shop. It's always been hard to shift and kind clunky when shifting gears. Finding neutral while the bike was running was nearly impossible. Last fall it became extremely hard to shift so I replaced the clutch over the winter, which was the first time I had actually been inside the primary cover. I could tell someone had been messing around with the clutch.....shoulder nuts rounded off a bit and the adjuster stripped just a tad, as well as the jam nut. Anyway, I replaced the clutch and adjusted everything out (1/4 turn) and I have maybe 1/8" of play at the lever. Fresh fluids in all three. I took it down the road and everything felt great! I could actually find neutral while the bike was running with a little rev. It shifted thru all six gears like a dream...and then it warmed up. Once everything warms up (about 10-15 miles down the road) it becomes extremely hard to shift in all gears. When shifting up you have to push down on the foot peg a bit before it will go to a higher gear. When shifting down you have to pull up on the foot peg just a bit before it will go to a lower gear. Very annoying! Once it's back in the garage and cooled down, you can shift all six gears just fine. I have a hard time believing a Baker OD6 with 14K miles is the problem and I'm still leaning towards something wanky with the clutch. Any ideas on what the problem may be? Anybody have any similar issues? Again, any help would be appreciated...
 

HMAN

I just like my Freedom
Supporting Member
Have u checked the trans fluid level? Hot gears will expand and make shifting tough. Also ck ur heim joints and the bolt on the external trans shift lever.
 

Bodie

Member
Have u checked the trans fluid level? Hot gears will expand and make shifting tough. Also ck ur heim joints and the bolt on the external trans shift lever.
Thanks for the reply. Yes, trans fluid level is good. Running Spectro for all three. I've checked the joints to eliminate drag issues or slippage on the external trans shift lever.
 

Jersey Big Mike

100K mile club
I need a little knowledge. Any help would be appreciated. Little back story first....bought an 03 Chopper several years back and thought I got a "good deal". Not so much! Right out of the gate I had to have the stator replaced at a local shop. It's always been hard to shift and kind clunky when shifting gears. Finding neutral while the bike was running was nearly impossible. Last fall it became extremely hard to shift so I replaced the clutch over the winter, which was the first time I had actually been inside the primary cover. I could tell someone had been messing around with the clutch.....shoulder nuts rounded off a bit and the adjuster stripped just a tad, as well as the jam nut. Anyway, I replaced the clutch and adjusted everything out (1/4 turn) and I have maybe 1/8" of play at the lever. Fresh fluids in all three. I took it down the road and everything felt great! I could actually find neutral while the bike was running with a little rev. It shifted thru all six gears like a dream...and then it warmed up. Once everything warms up (about 10-15 miles down the road) it becomes extremely hard to shift in all gears. When shifting up you have to push down on the foot peg a bit before it will go to a higher gear. When shifting down you have to pull up on the foot peg just a bit before it will go to a lower gear. Very annoying! Once it's back in the garage and cooled down, you can shift all six gears just fine. I have a hard time believing a Baker OD6 with 14K miles is the problem and I'm still leaning towards something wanky with the clutch. Any ideas on what the problem may be? Anybody have any similar issues? Again, any help would be appreciated...
First thing I would check is the HEIM joints on the ends of the shift rod. If they are sticky/stiff it will do exactly this.
Check the rest of the linkage as well. Make sure nothing it loose.
 

Bodie

Member
First thing I would check is the HEIM joints on the ends of the shift rod. If they are sticky/stiff it will do exactly this.
Check the rest of the linkage as well. Make sure nothing it loose.
I had already disconnected the HEIM joint at the foot peg and checked it out. I just visually check the rear HEIM joint at the tranny and hand shifted it....all seemed fine. After you and HMAN have both mentioned the HEIM joints, I went back and disconnected the linkage on both ends, and sure enough the rear HEIM is seized up almost completely. I have a set on the way and should be here is a couple of days. Also, I adjusted the clutch plates and lever according to the instructions provided by Mikeinjersey. It feels ready good and I have plenty of pressure plate travel. I'm hoping the HEIM joint is my issue for an easy fix! If not, I guess I'm cracking open the primary again, removing the starter, popping off the tranny top cover and inspecting the shifting fork.....and that just kinda sucks! Thanks for the help, Guys. I'll update in a few days...
 

Bodie

Member
Update for anyone you cares..... I ended up replacing the entire shift rod. Once I took the shift rod off, I noticed the previous owner had cut it down from its original size. I kinda scratched my head as to why you would do something like that until I took it for a ride. I remember him being about as tall as I am, which is to say we aren't. Bringing the shift rod back to its original size set the foot peg forward about another 1.5". Still a comfortable ride for me. Anyway, the bike shifts better than it ever has. The clutch actually feels "right". I appreciate the help and being steered in the right direction. If it wasn't for the help I'd have half the bike tore apart by now :D
 

HMAN

I just like my Freedom
Supporting Member
Update for anyone you cares..... I ended up replacing the entire shift rod. Once I took the shift rod off, I noticed the previous owner had cut it down from its original size. I kinda scratched my head as to why you would do something like that until I took it for a ride. I remember him being about as tall as I am, which is to say we aren't. Bringing the shift rod back to its original size set the foot peg forward about another 1.5". Still a comfortable ride for me. Anyway, the bike shifts better than it ever has. The clutch actually feels "right". I appreciate the help and being steered in the right direction. If it wasn't for the help I'd have half the bike tore apart by now :D
Good deal. Glad it was a cheap fix, cause cool aint cheap!
 
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