Transmission - does not like going into 4th gear

[ChopperJeff]

OK, go easy on me as this problem is not for a Big Dog, but being a devout Big Dog owner of the past, and knowing how helpful people are here, I thought I'd stop by with this question.

My bike has recently developed a problem when up-shifting to 4th gear. Namely, it just does not like to do it! Pull in clutch level, pull up on foot lever, release clutch lever, and I'm still in 3rd. Sometimes I need to try a few more times before it finally goes into fourth. Other times is will go in the first try.

On occasions it will act the same for 3rd, or will go into 3rd, and pop out during acceleration.

I've found that the tranny shift lever...the one that is attached to the spline shaft to the tranny...is loose. Got a new one on order as it refused to tighten any more, but wonder if that could be really be causing my issue, or do you think I'm looking at a tranny rebuild. The bike only has 28,000 miles on it.

In case you're wondering, it's a Proper Chopper 300RS I purchased a couple years ago.

 

[HMAN]

Be sure to check the heim joints on the shifter linkage and make sure they are free and lubricated.

 

[ChopperJeff]

Thanks for the input, but the heim joints are all very free and lubed. One thing though concerning the linkage from the front foot lever to the lever going into the tranny is that it is at a slight angle. I guess the motor sort of gets in the way if it were straight, but it does seem like it would have made it. I would think you'd want a straight shot from lever to lever, but maybe it's OK? Has worked pretty well up until a week ago.

 

[bigdogtech01]

Do you know who built the transmission that's in the bike? With that many miles depending on who it's made by, it might need a rebuild. Have you checked to see if for some reason the lock nut on the eccentric adjuster has loosened up causing the adjuster to move? How loose is the shift arm? You think it might be jumping the splines? Would have to be very worn to do this.

 

[ChopperJeff]

I have no idea who made the tranny. The manual for the bike is useless, and the only marking on the tranny says: *W05070877*

Doesn't seem like the shift arm is skipping splines on the shaft as once it's up against any force, it stops moving around the shaft. I'd say the play in it is about 1/4 inch, maybe a tad less. It also slides off the shaft, only being stopped from coming off as it bumps up against the inner primary. Not sure what you mean by eccentric adjuster. Is that something that reveals itself once I pop the top of the tranny off? In Googling this, I see a lot of talk about the shift pawl adjustment. Not that I fully understand that, but maybe once I peek inside, it'll make sense.

 

[bigdogtech01]

The eccentric adjuster adjusts the shift paw assembly. To adjust, you will be doing so in 3rd gear and there is a procedure for doing so...it's a very fine adjustment.
Does the shift arm kick back like it should? It seems like it has spring back to it? If not, the internal spring on the paw assembly might be broke.

 

[ChopperJeff]

OK, I'll look into the pawl adjustment. As for the shift arm kicking back, it does do so, as pressing it a bit in either direction results in it springing back to a centered position.

 

[ChopperJeff]

Got the top cover off the tranny, so the shift pawl adjustment should be easy to do now. Any thing else to look for while the cover is off? Is it possible to pull more off and look at the gears and forks, or does the whole tranny need to be pulled out?

 

[ChopperJeff]

The shift pawl appears to be centered, but can this really be done just by sight? I see that the spec is 0.01". Seems to me the use of feeler gauges is in order.

 

[ChopperJeff]

In looking at the shift pawl again, it appears that it is not really centered, when viewing the travel of the transmission lever in both directions, noting when the shift pawl contacts the pins. It moves a little less in the up shifting direction. Can this thing really go out of adjustment over time? The locknut is tight as hell, so there is no way it went out of adjustment due to it being loose.

Also, with the bike up on the stand, can one really expect the tranny to shift into all gears? It appears rotating the rear wheel is required for the tranny to shift. Is this normal? Just trying to verify that my problem truly exists while up on the stand, and any shifting problems I'm seeing are not due to me doing something wrong.

 

[bigdogtech01]

In looking at the shift pawl again, it appears that it is not really centered, when viewing the travel of the transmission lever in both directions, noting when the shift pawl contacts the pins. It moves a little less in the up shifting direction. Can this thing really go out of adjustment over time? The locknut is tight as hell, so there is no way it went out of adjustment due to it being loose.

Also, with the bike up on the stand, can one really expect the tranny to shift into all gears? It appears rotating the rear wheel is required for the tranny to shift. Is this normal? Just trying to verify that my problem truly exists while up on the stand, and any shifting problems I'm seeing are not due to me doing something wrong.

Yes, you normally have to move rear tire to get it to go through the gears. That's normal.
If the jam nut is tight on the eccentric adjuster, then the paw assembly might be slightly worn. You will need to put transmission in 3rd gear and center the paw with the adjuster, then lock the nut back down. Shift through the gears to see if this helped with your problem.

 

[ChopperJeff]

Thanks! One quick question... Is the jam nut a 17mm?

 

[bigdogtech01]

Thanks! One quick question... Is the jam nut a 17mm?

Same as clutch pushrod..11/16"

 

[ChopperJeff]

Just quick update:
Ended up taking the bike to the dealer as I just got tired of messing with it, and I lucked out! They adjusted the shift pawl and the primary chain, and the bike shifts well now!

I don't trust that the tranny lever (the one that attaches to the spline shaft) is going to stay tight, as it has loosened up twice prior to taking the bike to the dealer, but I bought the betterlever, and will throw that on if it loosens up again.

Thank you all again for you input!!!

 

[francoblay1]

Just quick update:
Ended up taking the bike to the dealer as I just got tired of messing with it, and I lucked out! They adjusted the shift pawl and the primary chain, and the bike shifts well now!

I don't trust that the tranny lever (the one that attaches to the spline shaft) is going to stay tight, as it has loosened up twice prior to taking the bike to the dealer, but I bought the betterlever, and will throw that on if it loosens up again.

Thank you all again for you input!!!

:2thumbs: