Possible bent shift fork??

[swcole]

Ladies and gentlemen, I was wondering if I could get some input on an issue that I am having.
Here it is: A 1999 Nomad, carbed with 90,000+ miles. When I shift UP to 3rd gear, there is no power and there is a metal hitting metal noise. But when I shift DOWN to 3rd gear, it works great. The issue is only with 3rd gear, no others. This happened on my way to work so I have not had the chance to try different things to see if it is an intermittent problem or constant. I looked at Gadjet’s page and a bent shift fork makes sense to me, but I also know next to nothing about this stuff. Any thoughts or ideas would be great, Thanks!

[MAS Tequila]

Are you saying that when you put it into 3rd it makes noise and doesn't go?

There are a couple of things it could be, none of them inexpensive to confirm or fix.

Bent shift fork, worn dogs, or a broken circlip.

The cases have to be split to determine which is the culprit.

Start looking for a low mileage used engine. A 1500 or 1600 from a Classic, a Nomad, or Meanie will bolt right in.

The cost of having a garage pull and rebuild the engine will be more than the price of a donor engine.

Or you could pull yours and rebuild it yourself, or rebuild a donor engine, if you have the patience. You'll acquire the skills if you're patient enough to follow the step by step in the service manual.

How do I know?

Been There Done That and Got The T-Shirt.

Give me a call if you want to talk about it.

MT
561-210-3399

[swcole]

MT,
Yep, that's what I'm saying. The bike will go into 3rd gear, you hear the metal slapping, but the bike does not go.
Thank you very much for the offer. More than likely I WILL be calling you because the plan is to rebuild it myself. While it's in pieces I'm going to look into over sized pistons and rings. They may be out of my budget, but who knows. I'll see.

[macmac]

Oh man that's just terrible news. At least you get a long season in Texas. All I can add is maybe do as MAS says for a quick fix, so you can ride, and then get your engine built back up any way you want. Then sell the other engine to get your money back.

[swcole]

Well, I started tearing into my motor and when I got the front bevel gear off I found the bearing for the output shaft is all bugered up:

http://i1217.photobucket.com/albums/dd389/swcole2003/2011-06-09130857.jpg

I plan on working on this again tomorrow to see what else is messed up.

[AlabamaNomadRider]

All I can say is good luck and hope it goes smoothly for you. Maybe the expense won't be all that great. You will save a ton by doing it yourself.

[swcole]

Gaskets alone is a little over $200, but while I'm in there I also want to put the oversized pistons and rings in. That will bump it up to around $500.

[cocheese72]

Gaskets alone is a little over $200, but while I'm in there I also want to put the oversized pistons and rings in. That will bump it up to around $500.

Sounds interesting, will that require bored out heads or different heads?

[cocheese72]

Let me know when all said and done, you have into it price wise. I think rings are $100, you say gaskets $200. Trying to figure out cost and time. I have issues, though mine is still very rideable.

[swcole]

The way I understand it, I will need to have the cylinders bored out, but I can use the same heads. But I am still checking on that.

[MAS Tequila]

Before you commit to boring, have the jugs checked. Mine just needed to be honed and new rings.

Also the heads are fine, just clean them up and check the tolerances according to the shop manual.

MT

[macmac]

Jugs/ clys get bored out to fit the pistons since they are bigger. I have no idea how much bigger'we' could go. It's too bad we can't get cams easier. Something over meanie cams and intake parts.

Right now before you do another thing, it would be a good idea to fix that bad bearing and test ride the bike, to confirm that is all that's busted up. Then do the project, if you still want too.

[swcole]

Yeah Mac, that's what I'm going to do. I got the bearing in and started putting it back together. I finally got my gaskets in tonight at 7pm, so I will continue working on it tomorrow.

I ordered the gaskets from Babbits online and I will never order from them again! I had to call them 3 days in a row to find out where my stuff was, when I talked to the supervisor Chane, he didn't care! What a prick!!

[swcole]

Well the ol' girl is back together and running too, imagine that!!!! I bled the clutch while putting it together, but on my test ride it was clear I didn't do a good job. I'll take care of that in the morning.

All together parts was about $200 and I have about 40 hours labor into it. Now that is starting/stopping over a period of about 18 days and a complete crankcase separation.

That was a big job, but as MAS said, follow the manual and you should be fine.

[Loafer]

Hope your problems are solved. Good riding to you.

[ringadingh]

Good for you that was quite an undertaking.

[macmac]

Send Chane a picture of yer ol self. I bet that will set up his mind different. I know it would fer me http://s2.images.proboards.com/grin.gif

[duneseven]

Nice!! I am glad you got it fixed I hope that ends your mechanical failures Congrats on a job well done!!

[cocheese72]

Well the ol' girl is back together and running too, imagine that!!!! I bled the clutch while putting it together, but on my test ride it was clear I didn't do a good job. I'll take care of that in the morning.

All together parts was about $200 and I have about 40 hours labor into it. Now that is starting/stopping over a period of about 18 days and a complete crankcase separation.

That was a big job, but as MAS said, follow the manual and you should be fine.

What parts did you end up needing?

[swcole]

Thanks everyone for the encouraging words!!!

The main part I needed was a 92045B-1190 which is a bearing for the output shaft. I was all buggered up!! The rest was just gaskets and o-rings.

[AlabamaNomadRider]

Glad to hear you accomplished the job and you are up and running again.

[ringadingh]

So the bearing was the problem and not a bent shifter fork, or were you able to straighten it?

[macmac]

Ring, I think it was his Bevel Gear bearing causing this.

[ringadingh]

Bill; you wouldn't of had to remove the motor and split the cases for a bevel gear bearing.

[macmac]

Ring I don't think he did. I think he was working up to it, and on the way found that bearing all crunched up. That in turn would make the output shaft act up, and so fishing 2nd gear or any gear not stopped would seem like a lunched trans.

How you doin' any way? The other day taking a shower http://s2.images.proboards.com/grin.gif I was thinkin of your injuries.

[ringadingh]

Im doing OK Bill; the casts come off on Tuesday, and then Im hoping to be back at work in a couple weeks.
Try not to think of me too much while in the shower ok, http://s2.images.proboards.com/grin.gif http://s2.images.proboards.com/grin.gif

[swcole]

Just to clearify, yep the bearing was the problem, but I did split the case. I was so far into it, I didn't want to replace the bearing but still have problems with the internals. Thankfully there was nothing bent, wore or ground down.

After it was together I had some shifting problems but they were self induced, I messed up but fixed it.

All in all, its all back together and running great.

[ridemslow]

For a '99, thats a dam good looking ride there. I like that paint job. Glad you got squared away.

[swcole]

Thanks! Wish I could say I did that, but I bought it that way.