2001 2nd gear repair final update.

[ppgflyer]

Great news - my VN1500-L2 is completely back together and running smoothly, no more 2nd gear pop-outs.

I spent multiple weekends tearing it down completely, replacing the transmission with a used one from a 2005 Classic. Everything was cleaned and re-assembled, new gaskets & o-rings as needed, new Barnett clutch spring and new Galfer braided lines.

The moment of reckoning arrived Saturday around 4PM, did I get it right? Jacked up the rear end to get the tire off the ground as I hadn't bled the clutch yet. Filled it with oil and coolant, cranked the engine first without plugs in to get oil circulated - no grinding noises . So far so good, put the plugs in and gave it a try, after about 5 seconds she fired up, high idle dropping back to low idle and smooth. Hand shifted the lever through the gears, all went in and out easily.

Stopped the engine and proceeded to bleed the clutch and rear brake, I was getting worried as the clutch would not operate but it was just a matter of perseverance, it apparently takes a lot to bleed the clutch, way more than the brakes.

Finished up on Sunday installing the new front brake lines. The lower left line turned out to be a real PITA, no way to remove the banjo bolt from the manifold under the headlight easily so it took longer than I expected to finish, the ride I had planned got put on hold but I did drive it home.

So far there are no oil leaks and no coolant leaks, the bike starts and idles just fine. Runs nicely and best of all = doesn't pop out of 2nd when I give it some throttle. Now it's time to ride, ride, ride, and then ride some more.

[ctrider]

Congrats, sounds like all the time you put into this project paid off in a good way. Enjoy the riding and stay safe.

[macmac]

2nd takes a beating on most bikes because guys abuse it. If you don't, it won't jump out of gear.

[MAS Tequila]

Cool, welcome to 'I have rebuilt it' club.

MT

[ringadingh]

Congrats on the job well done. Those clutches can be a pain to bleed sometimes. I had quite a time bleeding mine as well.

[Sin City Stan]

That's gotta be a good feeling!!! Good job.

[ppgflyer]

Originally Posted by ctrider

Congrats, sounds like all the time you put into this project paid off in a good way. Enjoy the riding and stay safe.

Yes, at least now I know the condition of my engine, inside as well as outside.

Originally Posted by macmac

2nd takes a beating on most bikes because guys abuse it. If you don't, it won't jump out of gear.

I agree and besides that, due to design requirements half of the face of the dogs that engage 2nd are machined away for clearance, this does not help at all so taking it easy on 2nd is a must.

Originally Posted by MAS Tequila

Cool, welcome to 'I have rebuilt it' club.MT

Thank you sir, and thanks for the pointers before I got started rebuilding it.

Originally Posted by ringadingh

Congrats on the job well done. Those clutches can be a pain to bleed sometimes. I had quite a time bleeding mine as well.

Thanks, I have a vacuum bleeder that helped a lot but you almost need a line going back to the reservoir so you can just circulate the fluid until all the air is gone.

Originally Posted by Sin City Stan

That's gotta be a good feeling!!! Good job.

Yeah, you can say that again Stan, I'm not sure my finger tips were up for much more abuse.


Next project, modified air intakes along with a TFI.