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Harley Davidson Expert
Re: Weird noise comming from the gearcase
Possible problem may be a loose push rod if you have adjustable ones installed. Otherwise either the cam bearings have collapsed (there was a recall on TC88 motors for this years back and Harley may conribute a goodwill repair if done by a dealer) or a lifter roller has broken.
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Go to your battery find out where that smoke is coming from. It sounds like summer your wires melted together. That was cause everything the short out, make sure your battery is charged, take it out of the bike and charge it and make sure you got about 12.67 V coming out of it. When you tested smoke coming from anywhere as bad. You could have some wires melted together file your wire harness, make sure that's not so
it sounds like you either blew out something in the gear case (pinion gear, ring gear, etc) or there is an issue with the midshaft/driveshaft. Raise the back of the bike up, put it in N, and rotate the tire, pinpoint where the clatter is coming from. My VStar 1100 did this, and I ended up getting a replacement used gear case for about 300 dollars.
The bad news is that if the problem is farther up in your drivetrain (in the transmission, or in the engine case) that will become a costly repair. With the bike raised up, carefully put it in 1st gear and observe if the driveshaft is turning....if it turns, that is a good sign, and helps to show that the problem could be in the gear case.
Use a digital camera when you start taking things apart so you have a reference to use when you put it back together.
sounds as though you will have to dismantle the engine and take a look inside and move the clutch around and see what happens. You can also take out the operation rod of the clutch and give it a good clean
You don't mention any other symptoms so I will assume the electronics, ie speedometer, tach, and such, did't start acting weird? If that is the case check your grounds these old rigid mount sportsters are known for vibrating the grounds loose.
You have some seriously bent shift forks. The guy who sold it to you did you no favors. If the bike is a 1998 model, most bike shops won't work on it. 10 years is the limit in most cases. Lots of shop mechanics repair older bikes at home. Ask around and find one.
This is a major repair. I normally tell people to take it to the shop just so they don't get into such an involved project.
The motor comes out of the bike then turned upside down for removal of the bottom case. The gears and shafts gotta come out so you can get to the bad forks. There's much more involved, but the idea is that you are better off having someone with experience do the repair. Do a new sprocket shaft bearing and crank bearings if the mechanic says so. Do new seals in any event. Call a dealer and ask what the cost would be to just replace the shift forks. Then add $75 to $100 more for bearings and seals. The home mechanic will cost about 25% less. Tough break guy. Sorry. Please rate this solution. Thanks
ry useing blue LOCTITE on the pinch bolts and other fasteners to keep the shifter from vibrating loose again. I had the shift linkage vibrate loose on my Thruxton when it was new, I had to fix it on the road to get home.