I have a 89 Sporty Project that I have just about finished. I got it running and noticed that when I revved the engine rpm up, I heard the clutch teeth engaging and the tranny pops out of neutral into gear. I have the correct type and amount of primary case oil, I have done the clutch adjustment as per manual and videos at least twice. I have tried to adjust my primary chain, though I have not tried the audible method described in the forum (YET).

I got the bike as a basket case, looked like someone was building dragger, motor completely rebuilt and primary gasket was new, never touched oil. I pulled primary case to get access to starter bolts, so I could reroute the oil lines which where hanging out. I noticed the primary chain was tight when I put it back together and did the adjustment. Since then I have had the issue with neutral and shifting.

I have yet to ride this bike as I just got it running and ready to re-enter into DMV (NO PAPER, but soon). I dont want to get on it and drive a couples miles to only blow the tranny or screw the primary, any and all help is accepted.

 

I have a facebook video with the exact noise the tranny makes, I hope this link works. scoll over to 5 min 10 seconds of the video and between 00:05:10 and 00:05:18 you will hear the noise it makes.

https://www.facebook.com/video.php

 

opps try agian.

https://www.facebook.com/video.php?v...type=2&theater

 

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*** UPDATE**** Sorry about the video non play. I pulled the primary cover and checked tension plate and chain. Looks good. A little more history, this project was purchased a couple years ago and has not been run or even had oil in it for several years. The engine and primary looked as if they were rebuilt completely. I checked as best I could and for all intents and purposes there been no oil added to the engine since the rebuild.

I did complete adjustments to clutch and primary chain as per instruction in both the manual and videos linked to the poor mans repair manual. The tranny shifts without any loud or obvious mechanical noises, but I can not find neutral. Finding neutral is like finding a virgin in California. Anything I have missed short of pulling the clutch and tranny?

 

Primary chain adjustment. Too tight and you will have problems finding neutral. Also you can try turning the adjustment nut out less.

 

I will give a try, again. I will also try a video to let someone hear what it sounds like when it pops out.

 

does it pop out of gear into neutral or the other way around???

 

it drops out of neutral when the engine revves, once out of neutral it very hard to find the to get back into neutral. It shifts fine with clutch but I just can seems to keep it in neutral or find it once it out.