So, long story short...
my bike ('97 Fatboy) is getting older and small booboos start surfacing (regretfully its not boobies).
I'm planning to do some repairs and want to adress them all in one downtime.

1. On a cold engine, she doesn't want to go from first into second gear unless going in high rpm in first gear before shifting. The footlever Just blocks. Once stuff warms up, she'll shift ok.

So...guess I'll start with checking clutch adjustment and primary tension?
Should I get a nuw tensioner while I'm in the primairy? This original one has about 70k Kilometers on her.
she gets lubed at regular intervals ;-)

2. Good one ;-)
seems to be a slight fluttering or tchirping noise from the lefthand side when Rolling on the throttle in low rpms.
When you whip her good, no noise heard, but that May be due to exhaust noise.
Was thinking (hoping) same primary/clutch adjustment problem.
Can't be intake/exhaust leak hissing.. no popping on decel?
Sound can only be heard under load at low rpm.
You guys know of other culprits to look into?

Evos are sturdy bikes and I love this one to bits.
she'll live for eternity if its up to me and I tend to give her all the tlc she needs to make it so.

All info welcome and winner gets free beer B-)
thanks.

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If it is the original clutch, you may want to have a look at the spring plate in the middle of the clutch pack. there are brass rivets that have a tendency to work them self out and cause issues in the clutch basket.

 

My '94 has had the same shifting issue for almost 200,000 miles. It began right after the bike was out of warranty. According to an article I read years ago by Baker Drivetrains, the problem stems from the second gear shift fork having a long reach, combined with a relatively short engagement on the shaft. This caused the shift fork to bind on the shaft when the transmission is cold. I've lived with mine because it only does it when starting cold in very cold weather. What I've found helps is to make the shift to second quickly, before the driveline slack unloads the gears. Works every time for me, and once it's warm, everything is fine.

Your second issue sounds like a loose primary chain.

 

Thx guys, Will be checking the primairy tension!
the rivets in the basket seemed fine last oilswap.

I will try that technique next time I take her out ;-)

I am also concidering switching to a different brand of oil (currently hd). Hopefully that helps with the gearproblem.

 

#2. This is a tough one. Noises are hell to chase.

Did you really check the spring plate in your clutch pack? It would mean you have to pull plates to inspect. Plate is #22 in picture.

Also, inspect your inner primary bearing, if your primary is on the tight side.

What does it sound like in neutral when you pull in the clutch?

Dave

 

Neutral sounds perfect!
the noise is more like a chirp, kinda sounds like a belt on a car engine that's juststarting to wear.
only happens when riding with little accelleration.
Ill do some experiments this weekend.

 

Check your belt tension. A slightly loose belt can cause a chirp when transitioning on/off throttle.