4th gear issue

TrapperAH1G · 12-20-2019, 09:20 PM

Okay, this is wierd. '01 Classic 1500 FI. Clutch spring replaced with Barnett 6 months ago. Recently "bike jerks and stutters" in 4th. No problems with other gears, shifting, down shifting, etc. Just "shakes and jerks" when in 4th. No strange noises, no grinding, nada. Goes into 4th easy & as long as you shift on into 5th without releasing clutch no issues, same going down. Can skip 4th with no issues, just can't use it.

Any similar experiences, issues......suggestions, solutions? (Other than just keep skipping 4th! I could already hear the gears in some of your cranial transmission turning to that!!!!)

Thanks

**ringadingh** · 12-21-2019, 12:23 AM

Its definitely an unusual problem, but I'd start by checking and verifying that the U joint is in good shape.A bad U joint can mimmick the problem you are describing.

Jesselkiko · 12-21-2019, 12:30 AM

Out of sheer curiosity, would the U-joint only affect 4th gear like the OP described? I would understand if it was in all gears.

**MAS Tequila** · 12-21-2019, 05:01 AM

Sounds like you have bent a shift fork, or the dogs are worn past the point of positive engagement.

TrapperAH1G · 12-21-2019, 07:25 PM

Thanks MAS. I was hoping to hear something else, but suspected what you said. My thought was the fork, but the cogs actually make more sense. UGH! If 4th is not used, would it hurt to ride it? Magnet on the filter, idle for a while, change oil and filter to remove metal first?

**MAS Tequila** · 12-22-2019, 02:11 PM

Quote:

Originally Posted by TrapperAH1G

Thanks MAS. I was hoping to hear something else, but suspected what you said. My thought was the fork, but the cogs actually make more sense. UGH! If 4th is not used, would it hurt to ride it? Magnet on the filter, idle for a while, change oil and filter to remove metal first?

I rode my 03 for over 20000 miles with the 1-2 fork bent to the point 2nd wouldn't engage.

Then while 200 miles from home, it broke.

RACNRAY · 04-06-2020, 01:42 AM

HIBent shift forks are "collateral" damage, they are not the cause of a gear NOT staying in engagement. As the dogs and/or slots wear and are unable to handle the load the gear moved by the shift mechanism gets "pushed out" and away from the other gear. Since the shift fork is held in it's position by it's engagement with the shift drum and has nowhere to go, it can only flex so much and is so rigid it will get bent, adding to the problem of the gear jumping out then back in.
RACNRAY

TrapperAH1G · 04-06-2020, 04:08 PM

Thanks for the input. He's still dealing with it, more so now that the riding season is approaching. Assume this is one of those situations where the decision is tear it down and replace/rebuild trans......or replace engine. Any advantage in going with a 1600 vs 1500? Is a meanie engine plug and play in a '01 Classic FI frame?

Stay healthy, ride when you can!

DragonLady58 · 04-06-2020, 07:53 PM

Well, the part that says seems like it goes into neutral, them slams back into 4th, sounds like a partly bent or perhaps broken shaft or gear...which isn't a easy fix, gotta pull the engine....
1600 engine swapout, complete bolt in and a nice upgrade, especially if a lotta miles on old 1500....

TrapperAH1G · 04-06-2020, 10:56 PM

My appreciation to each of you that have offered advice/help. I've forwarded this link to my son. Probably going to swap engine for 1600.

**smokier** · 04-11-2020, 07:01 AM

Hey DL, Just curious. Does a 1600 swap out into a 1500 frame need to include the ECU from the 1600? Is the rest of the wiring harness the same?

**MAS Tequila** · 04-11-2020, 12:55 PM

Use the harness & ECM from your bike.

It will be plug and play.

andyvh1959 · 08-12-2020, 07:20 PM

Sooo,.....I'm still riding my 1600 Classic which I have to double shift past 2nd to 3rd. Been that way over 3,000 miles since I took ownership of the bike from the PO. No idea how long the PO rode the bike without 2nd gear. I'll be almost 4,000 miles on the bike since I bought it by this weekend. I'm keeping my rides local, nothing far, until I tear it down this winter and replace the tranny with the MS tranny that I have for 1st through 4th gear. I'll keep the Classic 5th gear. Just hope it doesn't do to me that same as MAS.

12-20-2019, 09:20 PM	#1
TrapperAH1G Member Join Date: Dec 2017 Location: West Central Washington Posts: 194	4th gear issue Okay, this is wierd. '01 Classic 1500 FI. Clutch spring replaced with Barnett 6 months ago. Recently "bike jerks and stutters" in 4th. No problems with other gears, shifting, down shifting, etc. Just "shakes and jerks" when in 4th. No strange noises, no grinding, nada. Goes into 4th easy & as long as you shift on into 5th without releasing clutch no issues, same going down. Can skip 4th with no issues, just can't use it. Any similar experiences, issues......suggestions, solutions? (Other than just keep skipping 4th! I could already hear the gears in some of your cranial transmission turning to that!!!!) Thanks Login or Register to Remove Ads
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12-21-2019, 12:23 AM	#2
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	Its definitely an unusual problem, but I'd start by checking and verifying that the U joint is in good shape.A bad U joint can mimmick the problem you are describing. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
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12-21-2019, 05:01 AM	#4
MAS Tequila Join Date: Jan 2009 Location: Psychiatric Ward FL Posts: 3,429	Sounds like you have bent a shift fork, or the dogs are worn past the point of positive engagement. __________________ MT 2016 FLHP Psychiatric Ward FL VBA 936
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12-21-2019, 07:25 PM	#5
TrapperAH1G Member Join Date: Dec 2017 Location: West Central Washington Posts: 194	Thanks MAS. I was hoping to hear something else, but suspected what you said. My thought was the fork, but the cogs actually make more sense. UGH! If 4th is not used, would it hurt to ride it? Magnet on the filter, idle for a while, change oil and filter to remove metal first? Login or Register to Remove Ads
	0

04-06-2020, 01:42 AM	#7
RACNRAY Sr. Member Join Date: Sep 2011 Location: SOUTH FLORIDA Posts: 1,210	HIBent shift forks are "collateral" damage, they are not the cause of a gear NOT staying in engagement. As the dogs and/or slots wear and are unable to handle the load the gear moved by the shift mechanism gets "pushed out" and away from the other gear. Since the shift fork is held in it's position by it's engagement with the shift drum and has nowhere to go, it can only flex so much and is so rigid it will get bent, adding to the problem of the gear jumping out then back in. RACNRAY __________________ "TRUE HAPPINESS IS IN THE HEART, NOT IN THE OUTSIDE FIXES" WITH OVER 46 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION! "WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
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12-21-2019, 12:30 AM	#3
Jesselkiko Jr. Member Join Date: Dec 2019 Posts: 1	Out of sheer curiosity, would the U-joint only affect 4th gear like the OP described? I would understand if it was in all gears.
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04-06-2020, 04:08 PM	#8
TrapperAH1G Member Join Date: Dec 2017 Location: West Central Washington Posts: 194	Thanks for the input. He's still dealing with it, more so now that the riding season is approaching. Assume this is one of those situations where the decision is tear it down and replace/rebuild trans......or replace engine. Any advantage in going with a 1600 vs 1500? Is a meanie engine plug and play in a '01 Classic FI frame? Stay healthy, ride when you can!
	0

04-06-2020, 07:53 PM	#9
DragonLady58 Sr. Member Join Date: Jul 2016 Location: Somewhere South of Alaska.... Posts: 2,351	Well, the part that says seems like it goes into neutral, them slams back into 4th, sounds like a partly bent or perhaps broken shaft or gear...which isn't a easy fix, gotta pull the engine.... 1600 engine swapout, complete bolt in and a nice upgrade, especially if a lotta miles on old 1500.... __________________ --------------------- Don't start no schit, there won't be no schit.... My Sarcasm is directly proportional to the amount of Stupidity involved --------------------- VBA#03239 VROC#37400 VRA --------------------- 2014 Vaquero 2001 Nomad FI 2003 Street Glide (sold) 1500 Meanie, fresh rebuild (sold) 90s BUBF Bobber (sold) 2001 UltraCycle FatPounder (Sold) 1975 HD ElectraGlide (Sold) 1982 Kawasaki Z1 Chopper (Sold) Suck It Up & Ride! Last edited by DragonLady58; 04-06-2020 at 07:55 PM.
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04-06-2020, 10:56 PM	#10
TrapperAH1G Member Join Date: Dec 2017 Location: West Central Washington Posts: 194	My appreciation to each of you that have offered advice/help. I've forwarded this link to my son. Probably going to swap engine for 1600.
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04-11-2020, 07:01 AM	#11
smokier Join Date: May 2015 Location: DBQ Iowa Posts: 1,807	Hey DL, Just curious. Does a 1600 swap out into a 1500 frame need to include the ECU from the 1600? Is the rest of the wiring harness the same?
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04-11-2020, 12:55 PM	#12
MAS Tequila Join Date: Jan 2009 Location: Psychiatric Ward FL Posts: 3,429	Use the harness & ECM from your bike. It will be plug and play. __________________ MT 2016 FLHP Psychiatric Ward FL VBA 936
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08-12-2020, 07:20 PM	#13
andyvh1959 Advanced Member Join Date: Dec 2017 Location: Green Bay WI Posts: 759	Sooo,.....I'm still riding my 1600 Classic which I have to double shift past 2nd to 3rd. Been that way over 3,000 miles since I took ownership of the bike from the PO. No idea how long the PO rode the bike without 2nd gear. I'll be almost 4,000 miles on the bike since I bought it by this weekend. I'm keeping my rides local, nothing far, until I tear it down this winter and replace the tranny with the MS tranny that I have for 1st through 4th gear. I'll keep the Classic 5th gear. Just hope it doesn't do to me that same as MAS. __________________ My $1200 Vulcan, to start from.
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