| Author | Message | ||
     Sweatmark |
OK, low-sided my 2003 XB9S and broke the shift mechanism (sheared shift lever pivot bolt, broken shift linkage, road rash elsewhere). I'm gonna try to fix it, and this thread is a place to document my upcoming bonehead attempt. Reep and Saro have already provided some important tips regarding troubleshooting and primary disassembly - thanks! If anyone has comments or experience, please feel free to make history here. Background: 2003 XB9S with really low miles (about 3600), used as playbike and trackdays; low-sided on hydraulic oil spill and damaged shifter, handlebar, mirror, oil cooler shroud, and rear axle slider; bike was shifting poorly from 3rd to 4th prior to low-side, as noted during previous week's trackday; fluids always fresh; no prior crash history, but bike was bought "new" from dealer with 175 demo miles, and post-purchase inspection of bike noted damage from an undocumented crash during dealer's demo period (no, sob dealer never remedied the situation). Here's what the bike looks like post-crash:    I'm able to shift through all 5 gears without difficulty, using a vise-grip attached to the external shifter shaft spline. Released the clutch in gear to spin up the rear tire a bit before each upshift, the bike securely supported on PitBull trackstand. With direct mechanical connection to the shift shaft, can feel some resistance in the 3-4-5 sequence; already had some mis-shifts in 3rd to 4th, as noted during trackday last week, but didn't detect much notchy-ness when shifting through the OE lever and linkage. Scanned through the service manual for primary removal and can see it's straightforward... no clutch problems (at least within the clutch itself), so no clutch spring tool required. I've looked through the drivetrain section in manual, but not yet seen the "bridge" support Reep mentioned... is it bolted to the inside of the primary cover? Plan: (1) extract sheared pivot bolt; (2) install replacement shift linkage parts and road test; (3) adjust primary and clutch, road test again, shampoo-rinse-repeat; (4) pull primary if necessary to inspect/replace shift shaft assembly; (5) go deep if necessary. (*) evaluate Ulysses shift lever assembly as option, since uses both of the mount holes in primary cover and looks beefy... would rather have the external plate fail in a low-side that shear the pivot bolt. | ||
| Sweatmark |
Some links as reference: Shaiss' shifter (anything improved, Shaiss?) http://www.badweatherbikers.com/buell/messages/384 2/206776.html http://www.youtube.com/watch?v=g1oX0E43tF4 http://www.badweatherbikers.com/buell/messages/384 2/243889.html http://www.badweatherbikers.com/buell/messages/327 77/315743.html http://www.badweatherbikers.com/buell/messages/142 838/179818.html http://www.badweatherbikers.com/buell/messages/142 838/290978.html Note the Ulysses shift lever pivot mount shown in the last two threads. Wondering if (1) this is an OE piece; and (2) if it could be used to beef up the shift lever pivot in case of another low-side crash... if the two-bolt mount piece was flipped upside-down, then the pivot bolt location would be way the heck up and a bit back. Likely unusable, but definitely a stronger setup. What about a bespoke bracket similar in concept to the Ulysses' but with a couple of pivot bolt holes to allow fore & aft adjustment? A new thread from Hogs: http://www.badweatherbikers.com/buell/messages/32777/367885.html? (Message edited by sweatmark on June 11, 2008) |
