Unanswered...

Have you drained the transmission? Any metal bits, like gear teeth?

I assume there's no way you can get it to do this in second, right?

 

Well they always clunk a little.. Especially if you sit in neutral at a light. 07 TC (and 06 dyna) and up do it more as the clutch spins faster at idle than the earlier ones. If you are not having trouble finding neutral then it's probably OK.

 

I feel like there may be a misunderstanding regarding what the actual symptoms are... Are you saying that selecting first gear, letting the clutch engage, and starting to move feels clunky? If so, Max's comment above may be true. But you seem to be describing something different, that continues to present itself the whole time you're in first, not just during initial engagement. Can you be a bit more explicit with your description? If you cruise along at a steady low speed in first, is there something that continues to happen until you upshift, or is it fine at a steady parking lot speed?

 

Good point.. If it's a bit of a rattle, check the rear pulley bolts.

 

Actually re-reading it if it seems to jump out or skip, then 1st gear is likely bad.

 

Yes, it happens the entire time I’m in first. But only during acceleration. I can idle around a parking lot in first gear and it will do fine. And “skipping or jumping out” is a perfect description. I can’t make it do this in any other gear. 2nd-6th work perfectly fine. If 1st gear is gone, can just that gear be replaced? Or am I looking at buying a whole transmission?

 

You can rebuild the tranny. What needs to be replaced is countershaft first gear, the dog ring and the shift fork. You should also replace trap door bearings and gaskets. There may be some other parts needed. The primary needs to come apart so there is a number of gaskets and seal that should be replaced. Probably a good idea to change the inner primary bearing and seals on that side also.

 

ok so here’s the big question. Is this something I can do myself? I don’t know a thing about motorcycles. However, I am very mechanically enclined. I’ve built a number of hot rod engines and a tranny or two. Or is it worth the cost for the peace of mind of knowing a mechanic did it right? Will it really be that much cheaper doing it myself?

 

On second thought, don’t bother answering that. I’m letting a shop do it. I want to ride this bike and ride it soon. I don’t want it torn down all summer because I’m trying to stumble my way through a transmission rebuild. Thanks for all the info guys!

 

That's a good idea. There are a few special tools needed for the project..