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Sbaugz
Posted on Sunday, May 05, 2019 - 11:02 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

1999 S3 with 4000 original miles.
Over the winter I replaced the primary chain tensioner with the upgraded unit. Ever since I completed that job, neutral is damn near impossible to find. I literally have to shut off the bike and bend down and use my hand to ever so slightly pop it into neutral. Any thoughts or tips?
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Jolly
Posted on Sunday, May 05, 2019 - 11:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Primary chain to tight will cause that exact problem. The book spec is wrong.
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Williamscottrobertson
Posted on Monday, May 06, 2019 - 01:23 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Too loose of a primary chain will cause it too. I go with about 1-1.5in of slop. too much primary fluid can cause it also - just barely needs to touch the teeth. Last thing it could be is the shift pawl adjustment, but if you didnít swap to the newer style detent plate thatís highly unlikely. You have to put the bike in second gear, loosen the pawl nuts and put a #32 drill bit in the hole on the detent plate, then rest the pawl against the bit and tighten down the nuts.
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Upthemaiden
Posted on Monday, May 06, 2019 - 09:22 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

1-1.5"?? that's some serious play. I know the general consensus is the manual measurement is too tight. Buellistic recommended 3/4" if I remember right, but that was letting my primary chain rub on the inside of the primary cover, so I had to tighten it back up a little and it's been good since.

I agree though, based on what you said, the only 2 things you touched was the chain tensioner and the oil... It's pretty hard to screw up the oil if you're just dumping in 1qt, so you'll probably have to mess with the chain tension.
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Sbaugz
Posted on Monday, May 06, 2019 - 04:59 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

allright, so i loosened up the chain and that took care of the neutral problem. Thanks.

Figured I might as well ask about my other problem as long as I have all your attention- seeing as its probably related. My S3 has always had issues shifting from the day I got it 3 years ago. I get a fair amount of grinding from time to time as I shift- like its not getting completely into gear. I also feel like I really have to forcibly shift between gears or they will do as described above. In particular, it happens going down from 2 to 1 and occasionally from 4 to 5 and 5 to 4. The bike only has 4000 miles on it, so I would be surprised if there was significant gear wear. Changing out the primary tensioner didn't really affect this one way or the other. Are there any adjustments or tricks that I should try?

(Message edited by sbaugz on May 06, 2019)
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89rs1200
Posted on Monday, May 06, 2019 - 05:21 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Too little, or too thick transmission oil, as can cable mis-adjustment will cause this problem.

* Adjust the clutch cable. After a few attempts one will get the feel for getting this right.
** Add a LOT of slack in the cable.
** Then adjust the screw on the clutch pack to specs. You will need the slack to get this adjustment correct.
** Pull the clutch several times, then recheck the adjustment of the screw on the clutch pack.
** Adjust nearly all the slack out of the cable.

* Also try synthetic Sport Transmission oil.
* Ensure the trans. oil level is checked while the motor is balanced standing straight up. No lean. Oil level should cover the gears on the clutch basket PLUS, about 1/8th inch more, to cover the machined ring above the gears.
* See the diagram in the maint. manual to see what I am talking about.
* Takes just short of 1 quart of Sport Transmission on my S3s.
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Sbaugz
Posted on Tuesday, May 07, 2019 - 07:04 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

ok thanks. I did everything you suggested 89rs1200. Maybe once this wisconsin weather behaves, I will be able to test it out. ..
I feel like maybe I had too much tranny fluid in there. I withdrew some, so hopefully that makes a difference. I am using mobil 1 V Twin synthetic but maybe I will need to switch to HD tranny oil if it still gives me problems.
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Oldog
Posted on Wednesday, May 08, 2019 - 01:23 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tranny oil will likely work better, M1 may be usable in the gearbox but the HD oil or similar is a better choice, one word of caution, the stator (alternator wirewound part ) and if your oil cleans off the varnish
well the primary has to come apart.
IIRC REDLINE oils should be avoided as they cause this failure.
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