Not Shifting fron 3rd to 4th

Energy One
Model: 2007 K-9
Sequence of events: Noticed clutch levr had some play so took play out via cable adjusting screw. Took bike out for Wednesday night bike night and everything work and shifted fine. On way home, got caught in torrential rain and clutch lever became very stiff and clutch felt like it wasn't fully engaging (almost as if my earlier adjustment was to much). Got home and next day readjusted cable to take pressure/tension off cable. Test rode fine. Next Wednesday went to bike night again but on way there had a hard time shifting into fourth gear, Clutch seemed to work fine (no late engagement walking at stop lights, etc...) On the way home and on thehighway, I could not toe shift from 3rd to 4th so I reached down and hand shifted with no clutch. When exiting highway, bike would not downshift from 5th to 4th until heavy foot applied. Limped home in 3rd gear. Next day performed clutch pushrod adjustment and cable adjustment (interesting to note that when I adusted rod I was able to turn 2 complete turns before getting resistance. Final rod adjustment is about 1 and a half turns back out from resistance. Also checked and lubed heim joints. Took bike out for test ride and still no shift from 3rd to 4th. 1st thru 3 and finding neutral works fine. Any thoughts of what could be going on?
 

Eric

Banned
I'd look @ the clutch nut..sounds as if its backing off.... its really easy to do.. if you want I got a printed version of the bdm service bullitin on that issue.. I could e-mail it to ya.. if you want it PM me your e-mail.& I'll send it to you
 
Been reading alot of posts on this issue (clutch and transmissions) and this was pobably going to be my next search and destroy mission. Just seems weird that the clutch nut being loose would cause no or hard shifting into 4th gear only. Yes, if you could, email me the BD sevice bulletin at Chris.Banaszak@dmas.virginia.gov

BTW: Do you need anew gasket when you take the primary cover off?

Thanks for the help!
 

Eric

Banned
have you adjusted the primery chain ? if its to tight it can cause shifting issues.. I use a new gasket.. but some have reused there old 1 & it worked.. e-mail sent on the service bullitin on the clutch nut.... if the clutch dosent disengage it will cause shifting issues also..
 
Thanks for the quick response. The service bulletin is some good stuff and answers some questions I had ( IE torque value of primary cover screws). Yeah, I plan to check how everything look (to include the primary chain) when I pop it open. Again, thanks for the info
 
With a special thanks to ERIC, the trouble boiled down to a loose clutch hub nut. Although it fit in with the symptoms of a maladjusted clutch cable and clutch pushrod, I didn't think it fit in with the symptom of the transmission not wanting to shift into 4th gear (gears 1-3 shifted fine) but damn if it didn't. Learn something new everyday. Again, all the previous post regarding clutch and shifting issues really helped. "Grasshopper is learning about the mystery of the Dog" :D
 

Eric

Banned
With a special thanks to ERIC, the trouble boiled down to a loose clutch hub nut. Although it fit in with the symptoms of a maladjusted clutch cable and clutch pushrod, I didn't think it fit in with the symptom of the transmission not wanting to shift into 4th gear (gears 1-3 shifted fine) but damn if it didn't. Learn something new everyday. Again, all the previous post regarding clutch and shifting issues really helped. "Grasshopper is learning about the mystery of the Dog" :D
glad it worked out.. those lose clutch nuts are tricky... the key words you gave me were you adjusted it then it got lose agin......:2thumbs: ride on....
 

shelty5

New Member
Can anybody help me on this? I bought a Big Dog motorcycle (2000 Husky). I have had troubles similar to the ones posted here about not being able to get it into neutral and it stalling while riding and backfiring. I have a mechanic looking at it, but we have not gotten to the root of all the problems. Can anyone point me in the direction of a big dog repairman in pittsburgh area?
 

HMAN

I just like my Freedom
Supporting Member
Can anybody help me on this? I bought a Big Dog motorcycle (2000 Husky). I have had troubles similar to the ones posted here about not being able to get it into neutral and it stalling while riding and backfiring. I have a mechanic looking at it, but we have not gotten to the root of all the problems. Can anyone point me in the direction of a big dog repairman in pittsburgh area?
http://www.bigdogbiker.com/forums/general/41105-best-bigdog-mechanics-each-state.html
 

bigdogtech01

Well-Known Member
Can anybody help me on this? I bought a Big Dog motorcycle (2000 Husky). I have had troubles similar to the ones posted here about not being able to get it into neutral and it stalling while riding and backfiring. I have a mechanic looking at it, but we have not gotten to the root of all the problems. Can anyone point me in the direction of a big dog repairman in pittsburgh area?
If your willing to drive a few hrs, I'm just up in NY.
 

Deathstar88

Active Member
hey bigdogtech.....i need a good tech as well. have some issues. can you PM me with a contact number? Im near Scranton PA
 

Dragonslave

Active Member
I had the same problem with my Clutch becoming too stiff and it turns out my needle bearing busted on me. Replaced and now good to go.
 

Deathstar88

Active Member
I had exact same problem. pulled tranny apart. gears are fine. however the little piece connected to the shifter that actually moves the gears broke off !! its basically just 1 piece that broke. waiting on parts from baker. Why would that break??? Would adjusting the clutch cause that part to break? I never had a problem with anything tranny or shifting related.
 
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