| Author | Message | ||
     Smitty808  |
I decided, being a Honda Motorcycle service tech., that I would pop the primary cover off the old S1 before the riding season, and see what was causing the shifter to bind last year. Everything was moving along nicely(honestly I've never even seen a Harley motor open before...except for the head gasket I changed last year.). I figured...hey...it's a motorcycle, how much different can it be?? First of all...I gotta' catch the Snap-On man next week....because I had to borrow tools from one of the other techs to get the first bolt out. Then I made the fatal mistake....the shifter was being a pain to get off the shift shaft...so I GENTLY pried it(no really!! gently!!!) Maybe it was already cracked...I don't know, but it split right in half!!  The good news is...I am headed to the Harley Dealer tomorrow anyway to get my free Buell hat, so I can price parts. The bad news is....I probably can't afford them!!! If anyone happens to have a spare laying around they could part with, shoot me an email to smitty808@hotmail, and give me a price! | ||
| Bluzm2  |
Smitty, You're in good company! Lots of folks have done the same thing. They sure are fragile buggers aren't they? The arm shouldn't be too expensive. You can get a complete replacement for about $100. It's the style on the 2001-2002 S3's, X1's and M2's. I don't remember which of the 2 styles fit the S1. Main difference is the shift lever length. Good luck! Brad | ||
| Spiderman  |
If your shifter is "binding" up it could be one of two things. 1 the shifter assembley that rolls the drum could be out of allignment. Easy fix. put the bike in third gear get a #32 drill bit I believe, you are going to want to check the manuel to be sure. Lossen the two bolts that hold on the shifter assembly that rolls the drum, stick the bit in the hole in the detent plate push the assembly onto the bit and tighten the nuts. #2 Your shifter forks could be screwed and well thats a whole nother story. PS that shifter shaft should be round 50$ | ||
| 1313  |
Spidy, You're right! It is a #32 drill bit. 1313 | ||
| Bluzm2 |
Don't forget to check the primary tensioner. Replace it if it's the old thin one even if it's till ok. It WILL break. If it's already cracked, it can cause crappy shifting. | ||
| Sportyeric  |
Pins walking out of the detente plate? | ||
| Reepicheep  |
I've had those shift forks in my hand, and REALLY doubt you bent them. I know that is a common problem on import sport bikes, but bet it is extremely rare on a Buell. I did notice a lip on the shift drum formed by the pins that move the shift forks, and filed it down a bit when I had mine apart on the Cyclone. Pulling the tranny on an S1 is a breeze. Once you are far enough in to adjust that shifter pawl position with the drill bit, you are only about 5 or 6 bolts from having that transmission out and on your bench. You can even completely dissassemble it with enough determination, patience, exploded parts diagrams, and some sacrificial PVC pipe (there is a bearing in there somewhere you have to pound out by the outer race). But it's probably just your primary chain tensioner with a split back plate, or the little retainer clip on the shift drum. Pictures are here, and the difference between the old and new style tensioner is obvious. If it is the old style, replace it. The crack can be hard to spot unless you remove it. Are you using the old bow style shifter? I think I have parts in the garage, don't remember if I sent them to the guy that bought my shifter or not, I think they are still there. I would recommend the new style part, it works a lot better, but free is free. Let me know, and I will go look for the old part. I generally left it in the tool box to use it to excercise the shifter when I had the thing apart. | ||
| Smitty808 |
While I'm at the dealer I will go ahead, and check the price on the tensioner too. What do you guys recommend for lubricant?? Is there something equal to, or better than the sport-trans fluid?? What is that?? It smells like motor oil in mine. | ||
| Reepicheep |
Mobil 1 Fully Synthetic Gear Oil. Best bang for the buck "upgrade" my Cyclone ever saw. | ||
| Al_lighton  |
Smitty, The arm on the shift shaft is cast and quite fragile, you certainly aren't the first to split one. Ours works and looks a little nicer if you're gonna keep the stock boomerang, and lets you adjust the force/displacement. See here  If you're going into the tranny, you'll be pulling the rotor and clutch basket as one. Helps to have one of the locking bars, go visit the primary thread here and see the picture I posted there of one. Makes quick work of the bolts. Note: your clutch basket bolt is left hand thread. ANd upon installation, thoroughly degrease those threads and use loctite per the manual. You DO have the manual, right? Read reepicheeps post again. In fact, read all of them, he's our main Primary poster boy since he had to take his apart and replace more than most of us have had to. His posts are all thru the Primary/Tranny section of the knowledge vault, and theres some good info and pictures contained therein with just a little digging. If I was you and had the rotor off, I'd be replacing that main seal at the crank output shaft. In fact, I WAS you, I just had my rotor off to replace my stator on my 99 S3, and decided to do just that. When I went to remove the old seal, it crumpled into pieces. A major leak at that seal was imminently in my future, I'm glad I replaced it. It may be motor oil in there, Buell techs now dump the 20W50 synthetic that they use in the engine in there. Personally, I prefer gear oil. If for no other reason, that I can instantly identify a leak as from the engine or Primary be smell alone. Al | ||
| Wyckedflesh  |
Yup, BURNT Mobil 1 75w90 has a stench that will cause all within 1 mile to know your leaking primary or frying your clutch/stator  | ||
| Smitty808 |
Thanks for the info guys. Priced my parts today(and got my free hat!!  ) It looks like I can get the Mobil 1 for just a little less than the sport-trans. And Al the search engines had already led me to that fine little part...looks like it's about $10 higher than the dealer part...but, I would rather cough up the $10 for billet, then break another if I do this again. Plus...it's not chrome. I would love to replace all of the chrome on my bike(please feel free to hate me now). Yes I have the factory service manual, and have been wearing it out the last couple days! Always nice to have a heads up on left hand threads!!! | ||
| Bobpaul  |
Smitty, Yes I broke my shift lever too! It's a cheezy die casting. There are so many things to check when you open up the primary. I ended up opening mine up about three times when I should have just "bit the bullet" the first time and checked the alternator stator, replace the primary tensioner (only about $20), shift drum and grease (or at least clean and re-oil) the end of the transmission shaft. When removing the crank nut you need a good way to keep the clutch from turning. The link bar that Al recommend is probably a good way to go, I eneded up using a piece of aluminum I had sitting around, that was after I bought the "hamster stairs" from my local HD dealer and found that it doesn't work. As soon as I put some real tension on the wrench the hamster stairs shot across the garage like a bullet and put a dent in the lawnmower! | ||
| Reepicheep |
Bobpaul, was that before or after the entire assembly (including your breaker bar) splashed into the open pan of tranny oil? I think I could put that pan in the next state, and the locking link and tools would STILL find some way do dive in the thing before I finished the job. Smitty, I will try and check the toolbox tonight for that shifter part. Its yours free if I still have it. | ||
| Smitty808 |
Ok...I got back to work today(another plus of working at a bike shop...I can store the Buell there!), and got the side cover off...and found this! It's always good to find something broken, so I can stop looking(even though I looked further!)  Reepicheep,if you really don't need that part,I would be very thankful for it.I will probably replace it eventually...but money is tight right now, and it's warming up outside! Oh...and by the way, it was the little piece that holds the clutch cable that I dropped in the pan of oil!! (Message edited by smitty808 on February 03, 2005) | ||
| Reepicheep |
I will look tonight and let you know. My "prosthetic brain" (PDA) will beep at me at 10 pm tonight and remind me to look for it. Glad it's just the tensioner! Thats an easy one. You will need a new primary cover gasket if you have the old paper one. The new metal ones are more expensive, but can generally be reused at least twice if handled carefully. I reused the derby cover gasket a boatload of times with no problem, as well as the shifter seal and the primary chain inspection cover seal. Have you had any evidence of oil being sprayed out on your rear fender, or lots of it up in the tail section of the bike? At 15k miles, a tuber is likely close to be ready for a new crank seal, and you are but two bolts away from getting to it (big freaking monster bolts, but just two of them nonetheless). Brings back fond memories. I think I will go out in the garage tonight, pour a bottle of gear oil in a pan, and drop my socket wrench in there just for old times sake | ||
| Reepicheep |
Smitty... I looked high and low, and can't find the thing. It either got buried in the move, or sent to the guy that bought my old Cyclone (though I could have sworn I did not, I put on a very nice banke shifer for him so he had zero use for it). I will keep looking, but checked all the obvious places, so you might want to start pursuing plan B. C'mon all you buellers out there, surely somebody who upgraded to the newer shift linkage has this thing sitting in a box somewhere!!!!! Step up! | ||
| Firemanjim  |
Is it the same as an S-2?We are just talking about the shift arm with the splines--looks like a sportster part? | ||
| Smitty808 |
looks like this:  | ||
| Reepicheep |
Doh! That looks a little different then mine anyway. Mine did not look that nice, but was the same basic shape. | ||
| Firemanjim |
I got one,probably no where near that nice.Send address. | ||
| Smitty808 |
Go quality....not show quality!!! I don't care if it shines...I just wanna' ride!! I sent you a PM with my address Firemanjim. Let me know if I owe you anything, for the part...or the shipping. | ||
| Smitty808 |
Got the shifter in the mail today Jim....Thanks!! I will get it screwed back together....and then hope for more warm weather!! I am indebted to you!! |
