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  • Mid gear problem

    Having trouble with my 2000 road star. Starts and runs great but when I go to shift into gear and let off the clutch it is making a grind noise. I can feel it in my drive belt. Can't figure it out and wanna be riding soon. If anyone has any ideas or fixes let me know please.

  • #2
    Pull off the front pulley cover and see if the pulley is loose(common issue) Also inspect the splines on the shaft that the pulley sits on they may have stripped if the pulley come loose. If the splines are good remove the nut clean the threads and use "RED" loctite when you reassemble it. Tq to spec and bend the washer tabs in as many spots as possible usually on 1 full flat and around a point of the nut so that it wraps a portion of 2 flats.

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    • #3
      What Dave said. BTW, does it only make the noise when you're moving? Does the noise get louder or rise in pitch as you rev the motor or go faster? I.E. is it speed dependent or RPM dependent?

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      • #4
        On the basis of only what he said... sure reads like his pulley and shaft are already gone! More specific details would help... But, it sounds like he's got some work cut out for him.

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        • #5
          Originally posted by Questcap View Post
          On the basis of only what he said... sure reads like his pulley and shaft are already gone! More specific details would help... But, it sounds like he's got some work cut out for him.
          I agree but that is where he needs to start looking. If it was me and I found a stripped shaft I would probably look over at my welder and consider welding the pulley to the shaft. The worst that could happen is I would be in the same place as I was in now (messed up shaft)and have to replace the same items if it didn't work so there would be nothing lost.

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          • Brad_G
            Brad_G commented
            Editing a comment
            Would the seals in there take the heat transfer from the shaft if you start welding in there?

        • #6
          Originally posted by davej View Post

          I agree but that is where he needs to start looking. If it was me and I found a stripped shaft I would probably look over at my welder and consider welding the pulley to the shaft. The worst that could happen is I would be in the same place as I was in now (messed up shaft)and have to replace the same items if it didn't work so there would be nothing lost.
          True... Cept he'd have to cut the welded pulley off if it doesn't' work, and *that* would be a bitch. I say call an audible. if it looks half way decent, weld that sucker and never look back! If not? it'd be a lot easier to replace the shaft. It's not a difficult job.

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          • #7
            Curious about the use of the mid gear. After seeing Lucky's Black Diamond build. I wonder if the mid gear is really needed? Does it change the gear ratio from the engine? Why is it even there? I know a front pulley works best the closer it it to the swing arm pivot. Maybe that's the reason? Seems to me that someone could covert a pulley to work off the output shaft I think it looks much nicer without it. Especially on Lucky's bobber. Color me ignorant if you want. I can take it. Been married to the same woman for 41 years so there's not much I can't handle.

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            • #8
              Originally posted by Doc_V View Post

              True... Cept he'd have to cut the welded pulley off if it doesn't' work, and *that* would be a bitch. I say call an audible. if it looks half way decent, weld that sucker and never look back! If not? it'd be a lot easier to replace the shaft. It's not a difficult job.
              Only have to grind the weld. As far as heat transfer I think a water hose on the back side of the pulley would insure anything bad from happening. You can also get a heat paste that I have used and it works well to help keep heat transfer from damaging things. I never tried the garden hose so I can't say for sure. If it destroyed the seal back to the other step "Grind the weld". If it worked go for a ride. here is a link to heat transfer paste.
              https://www.google.com/aclk?sa=L&ai=...9aACCEY&adurl=

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              • #9
                The mid gear, or transfer case set-up doesn't change the ratio of drive any. It does transfer the power output from the right, to the left side of the bike... but, if it comes down to just what it is there for, I think the only real reason is: To lengthen the bike, make it look like the trans is separate from the engine... and be just that much more Harley-esque. Others?

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                • #10
                  Actually, the transfer case gears do change the ratio by about 1.09:1. A 32 tooth gear is driving a 35 tooth gear via the chain. Click image for larger version  Name:	B001055A-58EC-45E5-9616-A74AF6ADE4E1.jpeg Views:	6 Size:	47.1 KB ID:	62994

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                  • Questcap
                    Questcap commented
                    Editing a comment
                    Oooo, now, THAT is interesting. Whose going to be the first to change or swap gears?!?!?!? Another new mod idea!!! Hahaha

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