TECH TORQ #127

Got a question for Doc Robinson, our Technical Editor? Email Doc at info@heavyduty.com.au

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Gearbox Problem

Doc, I had a 124-cube motor put in my 2010 Dyna and within 1000km the gearbox had broken – it’s associated with the shifter forks, I’m told. Is this common with higher horsepower motors than stock? I’d appreciate some of your wisdom and knowledge before I confront my dealer, as I have a bad feeling about this.

GEARBOX PROBLEM
Doc, I had a 124-cube motor put in my 2010 Dyna and within 1000km the gearbox had broken – it’s associated with the shifter forks, I’m told.
– Ralph

Ralph, I spoke with Craig Carling, a factory-trained Harley tech who now swings spanners at Adelaide Bike Works. Craig says they have encountered problems with late-model transmissions, mostly with big-horsepower motors. He said mainly third or fifth gear is where the problem exists. The shifter forks wear which affects the dog ring, causing the bike to jump in and out of gear. To the rider this may feel like a slipping and grabbing of the clutch. In the accompanying pic, Craig is pointing to a wear point on the dog ring. Metal particles from this will damage the bearings so it is essential they be replaced when the repair is carried out. Regarding approaching your dealer, this is a bit of a tricky one and may require some delicate negotiation. In a worst case scenario, he may claim that fitting the bigger motor caused the problem, and therefore your warranty is void. Good luck.

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