I have had many issues with my bike, 2002 1500 Drifter, all of them brought on by me. Most recently it's been a noise issue that I've not been able to figure out. It's a rolling noise, not engine. It sounded like some grinding for a minute. I've replaced all of the wheel bearings and the front axle and the noise has pretty much gone away but now I'm noticing that it's popping out of 3rd gear. I've had some historic 3rd gear issues, rough transition, etc. but now it's definitely popping out of gear. I'm guessing that it's a complete tear down of the engine?
Sounds like a shifter fork or other transmission issue. Maybe Troll can weigh in here... I know he recently had to replace the bevel gears in his bike, and his symptoms included grinding noises too... Think he also had popping out of gear issues when he got the bike, about 80,000 miles ago, if I recall....
Yeah, we've been talking about the bevel gear, but the shift issue might be something else. Make sure that the linkages and levers are all tight, just in case you're not getting it all the way into 3rd. No issue with 4th? the shift forks are 1-2, 3-4 and 5th by itself. Usually worn shift doge are the suspect parts. To rebuild the trans, the whole engine has to come apart....
Having the same problem with 2nd gear. Was told most likely worn dog or bent fork.
Yes, complete tear down. Thinking about an engine swap if I can find a good salvaged bike
for a reasonable price.
aralph