Swapping 1600 into an 03 1500cc Nomad

[andyvh1959]

Definitely have to study this entire thread, as I have to take down the engine on my VN1600 Classic to repair the failed 2nd gear issue. Most likely a failed shift fork. All the other gears shift fine, but 2nd gear will not stay engaged with even the slightest load on it.

[MAS Tequila]

Definitely a bent shift fork.

[andyvh1959]

I got a complete Meanie gearset for the eventual tranny rebuild on my Classic 1600, so hopefully I don't experience the challenges Colin did with replacement parts that were bad. Attached some pics of the tranny parts that will go into my Classic/Nomad/Meanie blend. The pic with the shift drum shows one side of the forks, the other pic shows the other side of the two forks. Visual inspection alone indicates they are good. So what does a bent shift fork look like?

The shift fork fingers look good on both sides, with a tiny bit of scuffing at the heel end of the fingers on two of the forks (visible if you zoom in on the fork fingers. The right most fork is the cleanest which I assume is the shift fork for the higher gears.

Also, visual inspection of the gears and dogs doesn't show any tooth or dog damage. So I'm hopeful the parts are good to go in. I'll use the 5th gear from my original Classic tranny to retain the overdrive of the Classic for highway cruising.

[andyvh1959]

Found this on youtube:

Interesting, pretty sure those balls under 2nd gear are for the positive neutral finder feature on Kawwy trannies.

Here is another good one dealing with tranny work:

[Mackavie]

Has there been any progress on this Colin? How did it end up?

Inquiring minds want to know!

[andyvh1959]

ME TOO! ME TOO!! I have the same project coming up later this year, and I've collected all the parts to make my style of Vulcan.