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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » 2002 S3T Shifting Troubles « Previous Next »

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Flying_finn
Posted on Saturday, January 10, 2015 - 07:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just picked up a 2002 S3T today with 6k miles. Shifted good during test ride and initially on my way home. After about 6 miles, started to get hard to down shift and upshift and eventually was stuck with only 5th for about 10 miles (sketchy). Was able to really use some force and get it to shift enough to make it home. I'd describe the feel as mushy and there is no grinding, it just goes into neutral when banging the shift lever. I can feel a click, but it does not engage. Just ordered a service manual, but am wondering if anyone has any thoughts while I'm waiting.
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Jim2
Posted on Saturday, January 10, 2015 - 08:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

You can use the s1 service manual here in the knowledge vault. First go through a clutch adjustment procedure. Second, primary chain tension check and adjustment. Ensure that the primary tensioner shoe isn't broken. If all that comes up short you will have to go into the primary cover and check the shift drum detent plate, retainer clip, and drum pins.
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Akbuell
Posted on Sunday, January 11, 2015 - 05:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It means taking the primary cover off and digging about, but if your bike has the same clutch pack as my X-1, the spring plate, better known as the 'grenade' plate, may have come apart.

After going through Jim2's clutch adj, primary chain, and primary tensioner checks, could do to look at the clutch pack.

Hope this helps, Dave
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Flying_finn
Posted on Sunday, January 11, 2015 - 07:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks for the tips. Didn't get a chance to tear into it today, but have been reading the manual. I'll update soon.
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Buell_bert
Posted on Monday, January 12, 2015 - 08:13 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My money is on the detent plate spring retainer clip.
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Flying_finn
Posted on Saturday, January 24, 2015 - 05:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well, it's not the clutch or primary chain adjustment. Guess it's time to dig into primary. Debating about Taking it to the shop. If I'm reading the service manual right I need a few specialty tools and a vise to get to the detent plate spring? Never have gone that deep into a repair before....interested in learning, just not sure I have the spare time and the space to do it correctly. How difficult a task am I really getting into?
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Flying_finn
Posted on Saturday, September 12, 2015 - 04:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well, long busy summer but finally got the Buell in for service. It was the detent clip as suggested. $84 in parts and materials and 5 hours labor - $387 at my local shop and she is shifting like a dream. Next up is replacing warped front rotor which arrives on Thursday. I'll be in great shape for Florida rising season
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Bluzm2
Posted on Sunday, September 13, 2015 - 12:27 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yikes!
The clip is $5 and a new primary gasket is about $25. I suppose there is a bottle of Formula + in there too. Another $10
If they took 5 hrs, you need to find another dealer. If you've done it before, you can do it in less than 1:30 without hurrying.
Ouch.

On the flip side, glad it's now working for you.

(Message edited by bluzm2 on September 13, 2015)
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Buellistic
Posted on Sunday, September 13, 2015 - 01:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

HARLEY-DAVIDSON and AFTER MARKET technicians making MECHANIC's and PARTS MEN out of BUELL RIDERS since 1983 !!!
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Froggy
Posted on Wednesday, September 23, 2015 - 11:05 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

For that brake rotor, outside of crash damage, warped rotors are rare. Usually it is a buildup of pad material on the rotor, or brake dust on the mounting hardware. A good cleaning can usually take care of the issue.
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