Transmission Problems - 6 Speed RSD Gear Changes

Discussion in 'Transmission' started by jamesn, May 5, 2011.

  1. jamesn

    jamesn Member

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    Hi guys, hopefully someone out there is able to help me...

    I’ve recently installed a 300 rear kit that was supplied with a 6 speed right side drive transmission, a Harley TwinCam casing with an Accessories HD 6 speed RSD builders kit. All’s gone well and the bike looks low and mean, as it was intended to. However, I’m having issues with the transmission and nobodies been able to resolve or provide a reason for the transmission faults that I’m experiencing, including the company who assembled the transmission nor the supplier of the RSD 6 speed builders kit.

    The problem I have is that changing gears between 1st to 4th work fine, they’re smooth and everything feels normal. But changing from 4th to 5th it’s not able to be done with the use of the clutch...as with all transmissions changing into top gear can be done without a clutch with sufficient RPM without harming the transmission, and it’s how many racers change into top gear. If I use the clutch it’s no go...impossible!

    Then once in 5th I’m able to changing through 4th to 6th, they’re smooth and everything feels normal. But when needing to change back down into 3rd...this change requires a boot, and once in I’m able to change from 1st to 4th again normally until needing 5th again?

    Neutral can hard to find and normally accessed via 2nd, i.e. first changing to 1st then into second and back down into neutral?

    I’ve correctly adjusted the shifter claws with feeler gauges via the top cover access so this is not the cause. I’ve also adjusted the clutch to meet the clutch manufactures specifications of minimum clutch disengagement so clutch is also not the cause.

    Strangely, at times there also seems to be a neutral between 4th and 3rd when changing down if the gears haven’t meshed correctly...at times causing me to touch the shift lever again which knocks it back into 2nd...not good, if at speed!

    Does anybody have any ideas of what could be causing the problem as I’m at a stage where I’m considering scraping the transmission and installing a Baker OD6 RSD transmission.
     
  2. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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    Since you have done all the adj and everything is in specs it looks like you may need to have the manuf. look at it. Was it made here in the states or does the manuf. have an authorized repair agent? What type fluid are you running in it?
     
  3. jamesn

    jamesn Member

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    Thanks HDDon, the tranny was assembled in the states as it was supplied with the 300 wide tyre kit. They've no agent here in Australia which doesn't help, although only this morning I finally received a responce from the supplier. They're still claiming it's claw adjustment causing it and recommend I adjust it in 3rd gear making sure shift lever travels evenly both ways...although I've done it more accuratly with feeler gauges through the top inspection cover and as expected the lever travel each way is even.

    After asking about warranty they've agreed to look into it further via a transmission specialist. They've also suggested I remove the cover again and go through all the gear changes to see what's happening. After romoving the oil tank 3 times now...grrr!

    At present I'm running HD OEM transmission oil...was thinking synthetic but at a later date. Do you think oil would solve the 4th to 5th and back to 3rd problem?
     
  4. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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    I don't know if a different fluid would change what is happening, but here on the forum even die hard Harley fans are reccomending Spectro 6 speed, probably won't hurt. With the even throw either side of 3rd it doesn't sound like it's a problem with the shifter forks, it almost sounts like there is something hanging 4th or 5th on the common shaft. Are 4th, 5th, and 6th helicle gears or is everything stright cut?
     
  5. jamesn

    jamesn Member

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    DDon, I'll be stripping the bike down again in a couple of weeks for final mods to the fuel tank (wider and stretched) and then final complete paint job (all sheet metal). It's had plenty of time on the road now to iron out the odd bug. Had an excellent 6 hour country run yesterday with mates...shocked them all with how well my sutup handles and they no-longer have the impression that fat rears aren't for long rides or unable to take corners.

    I was hoping not having to strip it down further for the final touches but it will be a good time to do so to get the bottom of shift problem...have a good look inside the box, run through all the changes. Being a new box it can't be too much...HOPE!

    I couldn't say if the gear cuts are different as I didn't realy take notice when adjusting the paws.

    Anyway, once again thank you for your thourghts and advice, I'll respond at a later date with what I found.
     
  6. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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    First-we are going to need some pictures of your build. It is not good form to tease the forum:D. I really don't think it matters if the gears are stright cut or helical, one just makes a little more noise than the other. This is either a misaligned shaft or one of the top gears did not get back cut and the torque on the gear teeth is causing them to hang together. I don't think this is a clutch adjustment problem either.
     
  7. jamesn

    jamesn Member

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    Hi guy's, I've finally finished my rebuild which I'm very happy with. Although I ended up purchasing a Baker 6 speed RSD. If you'd like to see pictures and know what went into it I've uploaded some to the softail members gallery and my profile, otherwise refer to BikePics - jnathaniel's 2004 Harley Davidson FLSTC Home Page on BikePics.Com for a good range of HD pictures.

    Regarding the Accessories HD 6 speed transmission problems, now that I'm finished my project I'll have time to get to the bottom of the causes of difficult shifting. However, when removing it from my bike I notice that the main shaft has almost 1/8" end float, so I suspect a missing spacer or something and from the other things that were wrong with the box it a true indication that the assembler didn’t assemble it correctly.

    Will keep you informed with the outcome.
     
  8. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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    First off you have done an outstanding job on this custom build!!! What a great looking bike. Second my hat is off to you for your perseverance, this type of build and the problems that come with building a ground up custom shows what a true bike builder you are. Last but not least you have picked my favorite color and the flames just add the finishing touch. Congratulations, Don
     
  9. jamesn

    jamesn Member

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    Thanks for the compliments Don,

    I've still not got to the bottom of my original RSD 6 Speed box, had 2 HD Tech look at it and can't fix it. There is 0.040" free play in the main shaft which indicates the problem but the manufacture (assembler) disargrees that nothing was leftout during the assembly and others no support. Glad I ended up installing a Baker.

    Anybody want a cheap box?
     
  10. Lawdog314

    Lawdog314 Active Member

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    Checked your pics out. Absolutely, drop dead gorgeous bike! :a Wish I had your talent, and patience. Happy riding!