Villageidiot destroys a perfectly nice sportster.

Discussion in 'Some Assembly Required' started by villageidiot, Oct 26, 2018.

  1. villageidiot

    villageidiot Long timer Supporter

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    Some DIS-assembly required.....

    So the sportster has been on the bench for a while, like months, and its time to get to the cause of the issue of it hopping out of first gear under load.

    so first we pull the primary cover, clutch assembly, and crank gear/rotor

    A889713E-8138-4C97-90E7-32B76C8A3E5D.jpeg

    this is what i was HOPING!!!! it would be, but the detent plate and clip looks great, though theyll be changed for the $8 in piece of mind.
    95DE9561-1492-4903-9576-D82D01022B55.jpeg

    ONWARDS, we pull the 5 bolts and take a look at the transmission gears. at first glance, it all looks good, but its kinda hard to see the shift dogs, etc with it all together.....
    8D996F4B-477F-4770-914F-E5B29AD47CD0.jpeg

    so we pull it apart. likely culprit of 1st and 3rd on the countershaft show some very slight rounded edges on the edge of the shift dogs, i cant beleive this is the source of the issue, but multiple threads on many forums lead to this.
    FA70CE9B-D572-42E2-9E14-B924FD43A080.jpeg

    so here we are until the parts come in, whats another $400 in parts after the first $8k. shoulda woulda coulda bought a new one for that. but it wouldnt be this cool!

    928F9C4D-59B1-4398-A6D5-CF0ACE6E4FE0.jpeg

    so we wait. parts are ordered, not sure what the timeline is, hopefully, ill have the trans buttoned up before we head to Europe on the 5th of September.
    madrider5150, AK650, JagLite and 4 others like this.
  2. villageidiot

    villageidiot Long timer Supporter

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    well i knew i should have done something. ill give mark a call tomorrow. bummer that i already ordered the stock gears, i dont know if mine are repairable or if i should just button it back up stock so i can ship it. dont want to get too (much more) outta pocket on this, but i definitely want it properly done.
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  3. sealsam

    sealsam Sam...I am. Supporter

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    Glad to see you refocus on this project.

    Get it done & move it out!

    Somebody is gunna get one nice dependable HD when you're finished.
  4. villageidiot

    villageidiot Long timer Supporter

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    That’s always the case. My nightmares make the next guys experience pretty damn good
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  5. sealsam

    sealsam Sam...I am. Supporter

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    Can't wait to see the buggy!!!!!!!!!!!!!!!!!!
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  6. villageidiot

    villageidiot Long timer Supporter

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    @fast1075

    Called the guys at R&D and holy cow, dude knows his shit. If I was going to keep the bike I’d be sending him the whole trans and let him work his magic, which is about $1000 plus or minus based on the “common” issues in the sportster. But I think this go round I’m just going to replace the parts as I see they need, and get it back together so it can be enjoyed by the next guy.

    Thanks for the recommendation, it truly is the RIGHT way to go.
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  7. AK650

    AK650 Long timer Supporter

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    Will have to check these guys out(thanks @fast1075). When I tear mine down for powder & paint, I should probably have the tranny made bulletproof.
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  8. villageidiot

    villageidiot Long timer Supporter

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    dudes are no fucking joke, will weld up the shift dogs, re profile, match etc, then they got some tricks for the shift drum including getting rid of the bullshit C clip. supposedly they get em shifting "like a jap bike"

    if i had an extra $1000 (about what it costs all in) to spend on the bike i would, but im having a hard enough time spending the $400+ on the parts i need to get it back together before it gets sold.
    JagLite likes this.
  9. AK650

    AK650 Long timer Supporter

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    Really good to hear, thanks for the info. As much time, effort, and $$$ as I have in it, may as well go balls out!
  10. villageidiot

    villageidiot Long timer Supporter

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    especially if youve got any performance mods to the motor (big bore, cams, etc)
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  11. fast1075

    fast1075 Not a Lemming Supporter

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    Hi guys. Ben a long sucky road. Major heart attack, kidney failure. Hospital to rehab, and back to hospital
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  12. villageidiot

    villageidiot Long timer Supporter

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    Shit! Sorry to hear. Hope you’re on the mend! Anything we can send ya to up spirits?
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  13. AK650

    AK650 Long timer Supporter

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    Thanks for being here, and hope things take a turn for the better!
  14. sealsam

    sealsam Sam...I am. Supporter

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    Been there, done that.

    It's no fucking joke, use it as a wake up call.

    Glad you're still with us brother!!

    All the best with the recovery, you'll get use to all the pills!
  15. JagLite

    JagLite Long timer Supporter

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    Puts things in perspective doesn't it.
    We never know what today might bring, for good or bad.

    A wake up call for sure.
    So glad you woke up in the hospital, waking up dead has got to be a bummer!
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  16. TUCKERS

    TUCKERS the famous james

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    vi......you know I owned a used car lot..so bear that in mind when I say..."you have already made a $400+ decision on the gearbox parts, so doing it right is ONLY a $500+ decision!
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  17. villageidiot

    villageidiot Long timer Supporter

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    yeah, except the "right way" wouldn't need new gears, they weld up the shift dogs and slots and re-profile them.

    its going back together with a new first and 3rd gear on the countershaft, as well as new bearings, clips, shift detent plate, retainer, and all new primary seals......good enough to satisfy a quality repair. that is, when the parts come in. hopefully ill have em for next weekend. Heather and i leave for europe on the 5th thru the 17th.
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  18. TUCKERS

    TUCKERS the famous james

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    Have a great and safe trip....we too are leaving in September....best time we think..after the schools reconvene!
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  19. villageidiot

    villageidiot Long timer Supporter

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    Gears are shipped and I should have them Thursday. Might be able to get this guy back together before the weekend.
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  20. TUCKERS

    TUCKERS the famous james

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    Take it easy Man!
    villageidiot likes this.