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Thread: Stuck in a gear after rebuild

  1. #1
    Join Date
    Mar 2016
    Location
    Portland, OR
    Posts
    29

    Default Stuck in a gear after rebuild

    A few years ago the motor was rebuilt by a fellow in Canada and was shipped back to me as a running engine. Not so. Had to reassemble and add the extras from the get go. I have tried over the years to work this out but to no avail. It is stuck in a gear and I cannot get it out of that gear. Even tried a short leverage bar on the selector lever on the transmission.. Any ides or has anyone else had this problem? I hate to remove the engine and drop the lower case if I don't have to. Clutch works fine so that is not he problem. Thanks for any help out there.

    Ben

  2. #2
    Join Date
    Dec 2011
    Location
    Falco Colo.
    Posts
    139

    Default

    morn n, cant sleep. this is kinda like a murder mystery. at first i thought ( Even tried a short leverage bar on the selector lever on the transmission )was the clue. but now i think the ( I hate to remove the engine and drop the lower case if I don't have to ) is the clue to what your working on. right? enjoy a good mystery. look n forward to more. gary
    gww57.com

  3. #3
    Join Date
    Sep 2005
    Location
    Sarasota, Florida
    Posts
    4,162

    Default

    I've had a number of Hendersons, and an Indian 4 and the problem you describe clearly warrants pulling the motor, and removing the bottom pan. Those engines are too valuable to diagnose from the outside, and only by looking inside will you find the problem. It doesn't take more than a few hours to have the engine out, and you can come up with a way of turning it upside down so you can leave the top of the motor intact. . . . Now, getting it back in the frame will definitely take more than 2 hours

    Eric Smith
    AMCA #886

  4. #4
    Join Date
    Mar 2016
    Location
    Portland, OR
    Posts
    29

    Default stuck in gear after rebuild

    Quote Originally Posted by gww View Post
    morn n, cant sleep. this is kinda like a murder mystery. at first i thought ( Even tried a short leverage bar on the selector lever on the transmission )was the clue. but now i think the ( I hate to remove the engine and drop the lower case if I don't have to ) is the clue to what your working on. right? enjoy a good mystery. look n forward to more. gary
    Thanks, Gary.I believe that you are correct, but i have held up hope for a simple solution. Ben

  5. #5
    Join Date
    Mar 2016
    Location
    Portland, OR
    Posts
    29

    Default

    thanks , Exeric. All my helpers have passed. But the pulling is probably the only way to. Ben

  6. #6
    Join Date
    Sep 2005
    Location
    Sarasota, Florida
    Posts
    4,162

    Default

    Ben, when I need help pulling a motor, all I hear are crickets If you do have to pull the motor all by yourself, just plan it out well, give yourself lots of room, and use a lot of furniture blankets to protect your frame, the motor, and your toes. I guess you could use a car engine hoist, or block, and tackle and lean the frame over. We humans are a creative bunch, just look at those pyramids
    Eric Smith
    AMCA #886

  7. #7
    Join Date
    Jan 2008
    Location
    S.E.N.Y. State American side of Hudson River
    Posts
    482

    Default

    Where are you located??
    D. A. Bagin #3166 AKA Panheadzz 440 48chief W/sidecar 57fl 57flh 58fl 66m-50 68flh 70xlh

  8. #8
    Join Date
    Sep 2005
    Location
    Sarasota, Florida
    Posts
    4,162

    Default

    Ben, I just now thought of a friend's Henderson that had the same problem. In his case, the shifter fork, locked up on the shifter shaft. He rode the bike often, but only for a few minutes at a time, and being in Florida, the humidity caused condensation inside the motor. I was shocked when I saw the condition of the ferrous metal parts inside the motor, which were covered in a flakey rust. Perhaps you can take the shifter fork plugs out of the case, and see if there is any problem with the shaft, and fork.
    Eric Smith
    AMCA #886

  9. #9
    Join Date
    Aug 2006
    Location
    So Cal
    Posts
    898

    Default

    two guys can pull the engine easy, hire a neighbor kid for a couple minutes - one you have some trust in. Good luck

  10. #10

    Default

    Howdy Ben,

    Realize this sounds fairly obvious but have you removed and inspected your shifter detent to make sure the ball is not seized in its bore. I would also look down that access to view the condition of the shaft and the detent groove. Some folks ratchet the adjuster down when they begin having second gear issues ruining the track and occasional the ball. Though it will require removing the rear fender you can also view the selector fork through the access door on the back of the top case.

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