Hello,
I rebuilt a 1973 Harley Aermacchi shortster. I starts and runs great, but it wants to pop out of gear. I have a service manual for it and know the shifter arm is adjusted properly. The bike was not running when I purchased it, so I'm not sure if this was a problem before or not. When I split the cases, I made sure I put it back together the exact same way it came apart. The gears and dogs looked good. Any suggestions before I split the motor again?
Thanks
Andy

 

When you split the cases did you make sure you didn't lose any of the gear set spacer shims? They often stick inside the case. Bad news is you will probably need to split the case again. There is a section in the service manual for checking side play, make sure you do it by the book. When you put it back together, did you use an original gasket or rtv? I have a couple of these little bikes, and if you don't shift them with some force, they will tend to pop out of gear. My gf has the issue when riding my z90, but I never do.

Is this a 72 or 73? The 73+ are 90cc, the 72 is a totally different bike and 65cc.

 

It is a 72 m65 Shortster. I was thinking I was going to have to split the cases, but was going someone might have a different suggestion. Thanks!
PS. New gasket

 

Good evening HotRod,
I have come into ownership of a shortster 65cc and am in need of a service manual but cant seem to find one, can you help?

 

Unfortunately HotRod posted this back in 2012 and only ever posted three times on HDF in that year, so it is unlikely you will get a reply. I recommend you start a fresh thread. Your local dealer may be able to supply a new FSM, it is certainly worth asking.

 

mr. t
i do not know if you have enough service time on the forum to be able to PM.
i think i may be able to help on the fsm,
click on my handle and see if pm is allowed, if so, send an address, do not post here on the forum unless you want the world to know.
if not, post back and i will see if i can get a link.
just checked your handle, looks like i can pm to you, so if i have the info, i'll send you a pm.

 

i have the fsm and parts book also.