Hey guys I was wondering if anyone has seen this before? I bought the bike totaled (mainly front end)it's a 95 1200 with 1200 miles on it yes 1200. When I finally get it back on the road it had a knock coming from the primary under load only and the primary Chain visually jumps up and down with the tension set correctly. Noise is under load only and goes away once the clutch is engaged. There is no noticeable play in the main or counter shaft and both spin freely. As for the clutch basket there is some play in and out but nothing I feel would cause this problem. I removed the clutch hub bearing today and it looks and spins fine. Also with the clutch installed I can spin it freely with out making contact with the end of the countershaft. So there's something that's cocking the clutch under load allowing it to hit the case, counter shaft and shift star. Any ideas on could be causing this? Any ideas would be greatly appreciated. Thanks!

 

Bump.

 

From what I see in the manuals the only way to get the clutch that close is from the
shaft being pressed in too far when under spring tension. Maybe the accident did a bit more than you suspected. Plus the ring gear looks like its getting chewed up a bit too.
Or someone replaced the CS bearing and didnt set it to the correct depth

 

What shaft are you referring to as being pressed in to far? Counter? Thanks for the input!

 

From what your describing, this could be a number of things. First that comes to mind is are you sure the visible damage shown in your pics is going on now or from a past event?? Next, I would take a close inspect of your primary chain, just another possibility. Next, how's the clutch hub for true, and is everything in the clutch basket that should be in its proper order? Another question, the clutch hub main shaft washer is directional / marked to be in the out position.

A HD service manual or equivalent really should be on hand for your best outcome with this kind of repair. Very helpful.

Good luck.
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