• Husqvarna Motorcycles Made In Sweden - About 1988 and older

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1986 430 AE pops out of gear

430auto

430auto

Husqvarna
A Class
I have my 86 AE running great. Only issue remaining is that it won't stay with the gears engaged. I can start off and then it pops out of gear.

I haven't pulled the side cover off but assume this is a broken spring at least.
I will be pulling the side cover off soon.

What do you auto guys think?

No grinding noises coming from inside there and the oil is new.

I'll post pictures when I pull the cover off.
Thanks.
 
I vaguely remember a mate having that issue and he used a rubber band to hold the lever in drive...there was something wrong inside but it wasn't terminal and he rode a couple of time like this... id pull the cover off asap...
 
430auto said:
I have my 86 AE running great. Only issue remaining is that it won't stay with the gears engaged. I can start off and then it pops out of gear.

I haven't pulled the side cover off but assume this is a broken spring at least.
I will be pulling the side cover off soon.

What do you auto guys think?

No grinding noises coming from inside there and the oil is new.

I'll post pictures when I pull the cover off.
Thanks.
Click to expand...
Likely the free wheel bearings (oneway bearing) on one of the gears on the counter shaft, is bad. Typically a worn free wheel bearing will grab on the initial shift and as more torque is applied it will loose its hold and the motor will feel like it is in neutral. Also check the engaging lugs on the disc drive and gear wheel it engages into on the trans main shaft. If those engaging lugs are severly worn it can cause the trans to pop out of gear. Hope this helps,
Marty
 
Pulled the trans cover and found 1 broken spring. IMG_2065.JPGIMG_2066.JPGIMG_2067.JPG
Not sure if they are different or if that is what they look like after stretching and about to break.
Can the spring be changed w/o pulling the drum off???
 
The first gear kits (430 and I guess 500 the earlier the gear is welded to the drum) I purchaced all had the ones shaped like the one above pictured in the plastic bag. All my 360, 500 and 420 have the other kind on the first gear clutch, they all seem to have the other kind on the big drum containing the other higher gear clutches. It looks to me like the later centers for the first gear clutch have two holes so either kind of spring can be used. I call the spring in the bag the pig tail one, the ones that are like gun blue are prone to breaking the ones of a more mottled grey more granular finish are the ones I was cherry picking instead of the ones that came with the kits. Consider yourself fortunate if you ran it with a broken spring, they can hang up on the lumps that contain the threads for the water pump.

I never could figure out how to change the springs without pulling the center but it might be possible with enough strength and the pig tail ones.

fran
 
The pops out of gear most likely is to be found after the first gear clutch assembly is removed and the next shaft is withdrawn. There are some cog things that engage on the far end of that, I do think the power only flows through the cogs in first so if it is popping out of a higher gear either I have a misconception or it will be something else.
 
fran...k. said:
The pops out of gear most likely is to be found after the first gear clutch assembly is removed and the next shaft is withdrawn. There are some cog things that engage on the far end of that, I do think the power only flows through the cogs in first so if it is popping out of a higher gear either I have a misconception or it will be something else.
Click to expand...
Yep, Frank is correct in the need to keep looking farther as broken clutch springs don't cause the trans to pop out of gear. I am thinking that the clutch springs broke and someone (the previous owner) tried to jam the trans into gear repeatedly due to the broken clutch springs and in doing so probably rounded over the the engaging lugs on the disc drive and drive gear mounted on the end of the trans main shaft. This engages the trans to drive and first gear. If it is "popping" out of gear on the higher gears then you may have a bad free wheel bearing. Either way you should pull the 1st gear clutch, and both trans shafts to disassemble them and inspect everthing.
Marty
 
Thanks guys. I will continue disassembling the trans. Now where can I get more of these springs? I know they pop up on ebay from time to time. I may have to look into getting a batch made since none of the vendors have them on their sites.
 
What's the p/n ? I think, I have a set from my Auto days, thought mine were green in color, mine was a 78 390AMX.
They may not be the same springs though?

Husky John
 
motomwo said:
Yep, Frank is correct in the need to keep looking farther as broken clutch springs don't cause the trans to pop out of gear. I am thinking that the clutch springs broke and someone (the previous owner) tried to jam the trans into gear repeatedly due to the broken clutch springs and in doing so probably rounded over the the engaging lugs on the disc drive and drive gear mounted on the end of the trans main shaft. This engages the trans to drive and first gear. If it is "popping" out of gear on the higher gears then you may have a bad free wheel bearing. Either way you should pull the 1st gear clutch, and both trans shafts to disassemble them and inspect everthing.
Marty
Click to expand...

Hello motomwo,

I know this is an older post, but the bit you describe about the worn lug sounds like my problem, thought I would verify.

So first the back story and what I found. I am the current owner of this bike now, 430 Auto decided to sell this one. After having done a little work on the bike, I tried taking it for a short test ride see what else needed work besides what I knew, and found it popped out of gear between about 5 and 15km/h, so I assume its slipping in 1st gear or when it shifts to 2nd. After this I began taking the transmission apart. When I got to the engagement gear for shifting the bike between neutral and drive, I noticed one of the 2 lugs that the gear fits between to shift it, was worn down. The second lug is not worn at all (it is on the side that would push the gear into neutral). I did check the gear itself, both sides of the teeth are mirror images of each other, teeth look fine and engage with the gear on the auxillary shaft perfectly, so I think I got lucky and the gear is fine. Looking at the 2 lugs, the worn lug seems to only be worn down about a millimeter at the very most compared to the unaffected one. Would I be right to assume that if the gear is slipping past this that the lugs are riding low on the gear if it only required a millimeter of wear on a lug to slip past? I am thinking this because the lugs are almost a centimeter tall, I feel the gear should sit deeper between them and if I pull up on the shifter on the outside of the engine, I can lift it about 7 or 8 mm upward. After repairing the lug should I shim the shifter up a little? I am having the lug repaired by a machinist because I can't find a replacement and because it was not worn very much.

Lastly when I did take it for a test ride to see what it needed, shifting to neutral was fine, it shifted solid into neutral, but when shifting to drive, it would shift into drive and keep going. It probably shifted twice as far as it should have, and once I looked in the transmission it appeared that it must have been shifting past the stop, and the gear.

Does it sound like I will be fine with a repaired lug and shimmed up shifter, or do you think its more likely the dog/one-way clutches on the auxillary shaft?

Thanks
 
Try and send pics of worn parts.
It is better to have an advice.
Have you checked the 1st drum clutch.
Must be screwed at 12( Nm ?)
 
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