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View Full Version : '94 sportster broken primary chain



jricharc
07-06-2014, 5:29 AM
I was out for a ride today and as I was shifting into third gear something happened and the bike wouldn't run. After getting it back home and pulling off the primary cover I discovered that the chain was broken. What could of caused this and what should I check for?

I had trouble getting it into gear when I was on the road but I assume it's because the chain was broken, this is my first bike so I don't have much experience with them in general so any insight would be helpful.

farmall
07-06-2014, 7:05 AM
Post clear bright pics. We are not mind readers. "Broke" is insufficient information. What precisely (hence need for pics) to the related parts look like? What do any chips and fragments look like?

Can you turn the engine over with a wrench and if so does it feel like it has compression?

Can you turn the engine over with a wrench (spark plugs removed)? Smoothly?

Jack up the bike with the busted primary chain removed, spin rear wheel then shift through the gears. Post results.

Download or buy factory service manual and parts book.

Since transmission didn't lock up and crash da bike, perhaps the engine did seize and the chain (fortunately for not crashing) failed under load.

jricharc
07-06-2014, 10:59 AM
Here are some photos, I will jack it up and see if it will shift or turn over.

http://i1278.photobucket.com/albums/y515/whiskey_bandit/2014-07-06125043_zps02954d63.jpg (http://s1278.photobucket.com/user/whiskey_bandit/media/2014-07-06125043_zps02954d63.jpg.html)
http://i1278.photobucket.com/albums/y515/whiskey_bandit/2014-07-06125027_zpsa8731dca.jpg (http://s1278.photobucket.com/user/whiskey_bandit/media/2014-07-06125027_zpsa8731dca.jpg.html)
http://i1278.photobucket.com/albums/y515/whiskey_bandit/2014-07-06125021_zps15ccea6d.jpg (http://s1278.photobucket.com/user/whiskey_bandit/media/2014-07-06125021_zps15ccea6d.jpg.html)

Elias
07-09-2014, 12:24 PM
never seen anything like that happen before, but i will tell you right off the bat you will need to take your trapdoor and tranny out and clear any possible shrapnel from getting between gears in your trans. take a magnet and feed it around the nooks and crannys there.

Elias
07-09-2014, 12:24 PM
what does your tensioner pad look like?

jricharc
07-10-2014, 1:35 PM
It was worn, it had three grooves from the chain in it so I went ahead and ordered a new one along with the new chain. I guess I will put it all together and see what it does?

seaking
07-10-2014, 1:43 PM
never seen anything like that happen before, but i will tell you right off the bat you will need to take your trapdoor and tranny out and clear any possible shrapnel from getting between gears in your trans. take a magnet and feed it around the nooks and crannys there.

not a bad idea, get this:

http://www.ebay.com/itm/MOTION-PRO-Clutch-Spring-Removal-Tool-Harley-Big-Twin-Evo-Sportster-XL-/181422252448?pt=Motorcycles_Parts_Accessories&hash=item2a3d9be1a0&vxp=mtr

You can also get a cheap impact driver at harbor freight (I'm assuming you'll need one for that tool.) and snap ring pliers. But (Elias) I thought that the trapdoor only shares oil w/ the primary, it doesn't look like it beat the shit out of the case or anything, if he didn't lose any teeth it might be ok. Maybe put another magnet somewhere to grab all that flotsam if you're overwhelmed with pulling all that shit off (OP).

jricharc
07-10-2014, 3:52 PM
I thought you could pull the clutch out as an entire assembly after you removed the nut?

jricharc
07-12-2014, 9:16 PM
Well got it pulled apart and got the new chain on and everything back together but it won't go into first gear now. Any ideas, I have not filled the primary or started it up but it shifts into neutral and high gears fine it's just first gear.

jricharc
07-14-2014, 11:26 AM
Well I found a tiny link logged in the primary keeping the shift lever from going all the way down into first. Now my only concern is the chain is tight and the new tensioner is all the way out, does the new chain just need to stretch a bit?