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Buell Forum » XBoard » Archive through September 08, 2012 » Strange Clutch/Shifting « Previous Next »

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Aldaytona
Posted on Friday, June 22, 2012 - 08:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

2004 XB12R side stand sunk through pavement and fortunately tipped over onto left side in the grass. No damage. Wasn't over for long and rode 10 miles home fine. A couple of days later, went to ride and bike didn't want to shift out of 1st gear. Adjusted clutch and checked fluid/linkage, still shifts strange. I'm stumped. D'oh.
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Natexlh1000
Posted on Saturday, June 23, 2012 - 07:21 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The inner lip of your primary cover may have popped. This seems to be a common failure among XB engines.

The lip I am referring to is the thin surface upon which the ball/ramp release mechanism sits.
You can check it by opening the inspection cover on the primary and pull on the clutch lever. If it's damaged, you should be able to see it.
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Ducbsa
Posted on Saturday, June 23, 2012 - 11:14 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I thought I had bookmarked it, but there was a thread about repairing the lip with an electrical box cover. I scanned the KV section, but nothing popped out. Maybe someone else can steer you to it?
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Sifo
Posted on Saturday, June 23, 2012 - 02:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Gunut75 was quite involved in the threads on repairing the broken lip on primary covers. I think he may have been offering his services to get the fix done. You may want to shoot him a PM if you verify this is the problem. I'm sure he will steer you in the right direction if that's the problem.
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Djohnk
Posted on Saturday, June 23, 2012 - 03:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

For your convenience, here's a thread with pics if you want to see what they mean by broken lip:
http://www.badweatherbikers.com/buell/messages/384 2/282980.html
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Brother_in_buells
Posted on Saturday, June 23, 2012 - 03:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

i was to slow!

(Message edited by Brother in buells on June 23, 2012)
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Aldaytona
Posted on Sunday, June 24, 2012 - 02:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks All,
Took the cover off, loosened the cable slack, but couldn't see anything broken (looking with flashlight behind the ramp assembly)off. Does the primary cover have to be removed to see the broken lip or is there another way to determine a break?
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Greg_e
Posted on Sunday, June 24, 2012 - 03:03 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you took the ramp off you should be looking directly at the lips cast into the cover, there is nothing else you need to remove to see them.
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Aldaytona
Posted on Monday, June 25, 2012 - 03:50 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I wondered how the ramp came out, or how hard it was to see behind it. I quickly glanced at the shop manual, but didn't see that page. Better take another look. D'oh
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Greg_e
Posted on Monday, June 25, 2012 - 11:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just unscrew the center adjuster and it will come right out.
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Aldaytona
Posted on Thursday, June 28, 2012 - 02:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ya'all hit it exactly on the head. Took out the ramp and the whole leading edge (lip) of the casting has started to crack off, just as smooth as it were machined. D'oh.
Gonna try to find an inexpensive one for temp use and do a perm repair like shown by Djohnk.
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Djohnk
Posted on Thursday, June 28, 2012 - 07:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I like the "Odie" solution the best:

http://www.web-reg.de/pf_addin.html

I wouldn't even mess with another "temp" cover. I would print out all these posts, take it to a good machinist (if you don't have a vertical milling machine), and get a quote. A good machinist could easily do it in a couple hours.

It's definitely a more permanent fix, might be cheaper, and they say the clutch works better on the steel lip.

(Message edited by djohnk on June 28, 2012)
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Argentcorvid
Posted on Tuesday, July 03, 2012 - 10:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

uh, you might want to check that last link.
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Thumpthump
Posted on Tuesday, July 03, 2012 - 04:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Please check your link, I would like to see another option.
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Aldaytona
Posted on Saturday, July 28, 2012 - 09:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks everyone, especially Odie, as I repaired my primary cover as close to his repair as I could. I didn't have access to a machine shop so I used a dremel tool and a cutting disc to trim the primary cover and cut the plate. It works, but the clutch cable now seems to border on being too long for the precise adjustment. Has anyone else who has made this repair run into this?
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