Stupid mistake putting the scoot together

[Nomad2day]

Be putting my 07 Bulldog back together seeing how it has been torn down for a number of reasons and made a dumb mistake. The transmission was sent out and I was changing out all the bearings and taking everything apart for cleaning.
Started putting it back together from the back up. Put the transmission in and then the swing arm and lined up the rear tire and transmission. Put in the battery box, some wiring and then assembled the front shifter controls where the sh?t hit the fan. Pieced it back together and then went to install the shifter linkage to the transmission and it is a inch or two short..Damn,damn, damn. When the shifter linkage was put on the transmission it was clocked to far back. Yes I can extend the shifter linkage out to fit but it goes almost to the end of the threads....:bang:
Of coarse you can not adjust the linkage on the transmission without pulling it back out or perhaps loosening the inner primary and pulling it back far enough to pull it off the shaft and rotate it....No I did not check it out before tightening the transmission due to the foot controls being off and dis assembled...To make matters worse, the rear pulley guard was bent somehow and did not line up with the pulley so I hit it with a dead blow to straighten it up some. Good advise is not to do what I just said. The chrome just flaked off where it bent..:lol: The chrome has already peeled off the headlight bucket.
Stopped here and went and had a few beers to think this out and stop destroying the scoot...Told the ole lady I needed a real good excuse if I was going to pull the transmission over getting a longer shifter linkage. A quick phone call and a stop by the house to pick up a side cover and off to the local powder coating business a friend of mine owns.
Looks like I am going to powder coat the rims, hubs, pulley bracket and headlight bucket now. Doing it all in a gloss or mirror black to match the bike.
Already pulled the rims back off and knocked the bearings out of the hubs and got it ready to go....
Anyway,
Lesson learned,
check the damn shifter linkage first..
Neil
At least I will not have to polish them anymore.....
Went and had a few more beers to think what else I could do wrong. Have not broke out the BFH like BB just yet..

 

[Eric]

OOPS !!!

 

[Daddycool]

Double Ouch!

 

[Guillaume]

No GOOOOD, Maintenance Manual before you start take the bike apart.

 

[Moespeeds]

If the shift arm on the tranny is too far back, you will have trouble getting through all the gears. Cut the appropriate allen wrench a little shorter, and see if you can get in there and loosen that arm and slip it off enough to rotate it. You should be able to. Just leaving it too far back and getting a longer shift linkage will probably cause an issue. If you can't get it with an allen wrench and don't feel like taking the whole damn primary off, try this: I'm going from memory here, but I'm pretty sure that if you pop the top tranny cover off and take out the shift drum, you might get enough clearance to pop off the C-clip holding the shift shaft from the outside. push it into the tranny a fraction of an inch, loosen and reposition the arm, then put it all back together. Cover the open tranny with a rag so you don't drop anything in there. It's a bitch, either way you do it.

 

[Nomad2day]

Thanks Moespeed,
I can take the bolt out of the lever with no problem but you cannot pull the lever out far enough to rotate it on the spline shaft due to it being against the inner primary. It 's no big deal now seeing how I am taking another path and doing some powder coating. I will just pull the transmission back out some and take care of it. I may take a look at what you have said now that I have time anyway to know one way or the other. I am able to shift it through all the gears. That much I did check but I will square it away anyway.

Guillaume,
I have a maintenance manual that I use to write in all my measurements,shims and etc. I go through it pretty much. It can be very vauge at best sometimes. It did not state anything about checking it that I seen anyway, but perhaps I missed it somewhere. I am not the first to it anyway good to know. Harley's are the same too is you fubar. It will be the last time I do that mistake but not the last time I take my scooter apart to work on it.:2thumbs:

You got to be able to laugh at your mistakes, share them, and move along...

 

[Raywood]

Neil, you getting lots of photo's for the how to one tranny installs??? :roll:

Can't wait to see the results of all you hard work.
Have fun,
Ray

 

[Nomad2day]

Neil, you getting lots of photo's for the how to one tranny installs??? :roll:

Can't wait to see the results of all you hard work.
Have fun,
Ray

:lol: Makes two of us........
My how too would sound like a song I think...
Put you transmission in and take it back out, put your transmission in and shake it all about you do the hokey pokey and you turn yourself about,
That's what is all about......:lol:

Neil

 

[Nomad2day]

Update..
The rims, hubs, pulley bracket and headlight bucket are out for powder coating in gloss black. I went ahead and pulled the transmission tonight and clocked the trans shifter lever to where the foot control lever is in the middle of it's stroke. I dropped one end of the shocks and then I removed the bottom bolts and loosened the inner primary bolts enough to slide it out far enough to remove the arm and clock it to where it needed to be. Tightened the inner bolts back up and left the bottom ones loose until I get the tire back on to line things up. I put some antiseize on the threads of the helm joints to keep them freed up.
Neil