INTRUDER1500.COM

September 11th, 2001

Never to forgive,
Never to forget!

Once I got the shift cover on and replaced the clutch slave cylinder along with the shift linkage, I tried out the shifter just sitting there on the floor using my hand. Crap...isn't right, shifts too easy, something isn't engaging. So using one hand I started moving the rear wheel... wait...it seems like it is engaging.

I put the large secondary cover on a bucket so that I could connect the rectifier, filled the bike back up with oil and then started it up. The rear wheel turns... outstanding...so I bolt the covers back on, lower the jack and head out for a test ride.

Almost instantly the first thing I noticed was the shifting was incredibly smooth and precise. You could definetly tell when it engaged a gear and it did it easily with much less force than I was used to. I head on out North of my house where there are some good hills. Pulled the first hill in 4th gear full throttle and up to 4500 RPM, bike stayed in gear (before it would have came out by 3700 at the most).

I did a couple of quick tests, everything seemed fine so I headed back home, cleaned up some and headed out for a long ride, namely because I know where there is a real nice long stretch of road... a field dyno-test. After 100 miles I'm convinced that my 4th gear popout is fixed. I was able to hit 5200 RPM in 4th gear and it stayed in gear and I did repeated 4th gear full throttle runs over 5000 and never once did it come out of gear.

My Conclusion...
The stopper comp arm assembly was extremely tight on my bike, certainly way over the factory specified 7.0lbs. I believe that because this was so tight the stopper comp arm was binding enough that the spring did not exert enough force to hold the stopper comp arm down into the valley's enough to keep the star from turning... thus letting the bike come out of gear.

I also think that because this was put together and tightened so tight there was some compression of the raised portion of the shaft, enough that the arm would now bind with the rear spacer causing enough resistance that the force of the spring was being overcome and allowing the stopper comp arm to not fully seat in the 4th gear valley.

I could be totally wrong, I'm certainly up for anyone that see's something I didn't or thought of something I didn't. Right now I can't force my bike out of 4th gear, where before I couldn't keep it in 4th above 3500 RPM. I have also noticed that shifting now seems much more positive, and smoother, although that may be a figment of my imagination, but it sure feels like a much more positive engagement on the shifter.

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