Just finished complete rebuild of the trans for my 65 FLH. I bought the bike a couple of years ago and had no idea about how it was treated prior to my purchase. The reason for the rebuild was that about 10% of the time it would not shift into 4th gear. Had to downshift back to 3rd then into 4th usually a few times to get it into gear. All else functioned fine. When I drained the oil, it was milky indicating the presence of water – ugh. Fortunately the only damage seemed to be that the main drive gear bearing and main shaft showed some rust and pitting from the water. Both were replaced with new parts. Everything was inspected and found to be in serviceable condition. Shift forks showed only nominal wear and were not bent. Shift dogs again, only slight wear. Bushings were replaced as necessary and also new shifter pawls and springs. Shift fork clearances measured and shims installed where needed. Alignment tool was used to set shift drum to shift forks. Everything worked smoothly on the bench both upshifting and downshifting. Slipped into neutral easily.
Once installed in bike I raised the rear wheel and again tested through all gears and worked like a champ! I was very pleased. However . . . when I got it on the road I cannot seem to shift from 1st to 2nd . It goes from 1st to neutral and that’s it unless I really smack the shift lever hard. Then it will slip in to 2nd without any clashing noise. 3rd and 4th are smooth as a baby’s arse. Downshifting back to 1st is no issue.
OEM mousetrap adjusted according to the manual. I have done this many times without issue.
Any thoughts before I pull the gearbox again? Maybe it will be obvious once I pull the trans cover and peer inside.
Once installed in bike I raised the rear wheel and again tested through all gears and worked like a champ! I was very pleased. However . . . when I got it on the road I cannot seem to shift from 1st to 2nd . It goes from 1st to neutral and that’s it unless I really smack the shift lever hard. Then it will slip in to 2nd without any clashing noise. 3rd and 4th are smooth as a baby’s arse. Downshifting back to 1st is no issue.
OEM mousetrap adjusted according to the manual. I have done this many times without issue.
Any thoughts before I pull the gearbox again? Maybe it will be obvious once I pull the trans cover and peer inside.
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