Bonneville America Forums Forums Technical Forums General Tech Clunks into gear

Hi Folks.

I have an 04 TA and have noticed lately [since Sat] that she clunks quite violently into 1st gear, and is quite rough going through other gears also.

Have checked chain, and if anything its 2mm on tight side.

Anyone any ideas?

How many miles are on your bike? I assume you checked the oil level and it is correct, but have you checked your clutch cable? If there's too much play or it's stretched, the clutch may not engaging or dis-engaging properly. It doesn't seem likely that the clutch would be worn out unless you have a whole lot of miles on the bike. That would be a question for some of the better mechanics on this board.

Less than 3000 on the clock, only 70 of which are mine.

The oil is reading halfway up porthole when engine is cold, and the play in the clutch cable is 2-3mm.

A Harley riding friend reckons its normal enough and probably something in the design of the bike, as the back sprocket visibly moves when 1st is engaged.

Harley riders are used to loud clunks when shifting, but our bikes are quite smooth. If the chain pulls on the rear sprocket when 1st is engaged, it is a clutch problem as it is not completely dis-engaged. Still sounds like a cable or linkage problem as 3000 miles couldn't wear out a clutch. I hope one of our forum gurus will respond as I'm not qualified. There is definitely help here. Ok guys, shed some light!

With the bike in gear and the engine off, pull in the clutch and see how much drag there is when you try to move the bike. If it hasn't been run in the last couple of hours, it's normal for the clutch to be sticky but it should break loose when you rock the bike back and forth a few times. If there is a lot of drag, the clutch isn't disengaging properly. Could be adjustment, might be a warped clutch disk or the wrong oil.

Check the play in the cush drive.

Not really helping here I know, but any possible faults aside, I like a clunky gearbox.

Sorta satisfying when it goes into gear.

Hondas I rode while training had nice clunky gears.

By-the-by, my America clunks into first and always has.
I've done nearly 21,000 miles on it too.

I think I'm with miniski on this one.

Greybeard's suggestion should be the first thing that you try. It sounds like clutch to me.

Clutch adjustment or malfunction sounds like the number one suspect. Just so you know, my TBA gives a healthy clunk when dropping into first. The rest of the gears are polite enough. That's been the way it is for 26,500+ miles. Reminds me I have a transmission.

change your oil

Agree with RB, change the oil, and use synthetic. Also there is a trick that I believe that I learned from someone on this forum. Before starting your bike for the first time of the day, push your bike a little ways in first gear with the clutch pulled in. Corse the bike will drag because the clutch plates are sticking, but this trick helps to break the plates apart, and you will get a much smoother engagement when you drop down in first gear for the first time starting out. It is part of my prefight when backing my bike down the driveway to warm the engine up, and has become a operating habit. I really believe that I am extending the life of the gearbox by this practice.YMMV Vegas

ditto vegas's post. but if the plates will not break free when cold there is an issue that will need to be addressed. if the clutch cable has never been adjusted since new that is the likley culprit.

It's not going to be the cush drive. Had mine out at almost 13ooo miles, and the cushions look like new. Mine has always clunked into first, usually only after cold starts. It may stop temporarily after an oil change, but only for a day or so. Does not seem to be hurting anything.

When you first drop your ride into first gear, have your rpms low. Seems the higher the rpms the higher the probability that the clunk will happen. Re adjusting the clutch cable, our bikes do not have an adjustment at the clutch basket. NOTE: Hardleys do. Hardleys cannot be adjusted soley at the handlbar side of the cable, like our bikes can. When your ride is running, place it in first gear, while holding the clutch lever in, try to roll your ride backwards. If you feel any resistance, then the trouble-shooting is the same as Greybeard mentioned. A barrel adjuster exist at the bar side of the cable. The barrel adjuster is slotted. Ensure the cable has not frayed at that location.

DOUBLE CHECK to make sure it's not frayed. It sucks having to find neutral without a clutch at the entrance to a roundabout with two choppers behind you....

Thanks everyone for your advice, definitely an improvement since I adjusted the clutch-cable, also i think i might have been a bit too enthusiastic when kicking for the gear.

I tried moving her with engine off in first gear, no problems there, very little drag.

Would anyone advise fitting a scott-oiler? I noticed today that with all the salt on the roads the chain drys up very quickly.

Thanks again

Get the oiler.

Set it and forget it.

I have the Scottoiler and love it! It's well worth the bucks.. there was a discussion over in accessories recently you might want to check out. Scottoiler

I may yet invest in one, though it still leaves the problem of hoisting the back wheel off the ground for cleaning the chain.

I tried leaning the bike slighty downhill and wedging a car-jack under one of the full-stand lugs [pics in gallery], and it lifted the wheel with ease and also seemed completely stable, though a proper jack would probably be the way to go.

People (including myself) have made home-made jacks out of 2x8s or a 4x8. I'll see if I have a pic of it... But it's cheap, and can tuck away in a corner of a garage, if that's all you need it for, it's great.

For what it's worth, my new '05 America "klunks" quite profoundly into first gear also (see "first gear" thread) and she only has 500 miles on her. Clutch performs flawlessly otherwise....does'nt matter if she's hot, cold, new oil, etc....I'm thinking this is normal....