Hello! New shifter kit issues

nonya0992

New Member
Dec 29, 2018
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Hello all. Im stationed in Korea right now and needed a way to get around since the Army wouldnt let me have a car. So I built a motorized bike. I recently installed a shifter kit. And let me say I will never do that again. But anyways, one of the issues I am having is that when I am in the higher gears my two chains like to touch. I spaced the sprockets further apart then the way they came but still having the issues. Also, my original bike chain didnt fit on the front sprocket that came with the kit. I had to bevel each tooth on the gear to get the chain to seat. Is this a common problem?

Here is my shifter kit. The outer black protective cover only has two bolts holding it since its not a load bearing member. But there are bolts under the black plate through the clutch cover holding the brackets on for the kit.


I rigged up a spring loaded lever to keep tension on the chain. The shaft to sprocket chain is the 415 chain that comes with the standard engine kit. The slimmer chain that came with the shifter kit was not long enough. If someone could point me in a good direction for the slimmer chain for this point I would be grateful.
 

Venice Motor Bikes

Custom Builder / Dealer/Los Angeles
Mar 20, 2008
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Los Angeles, CA.
Hi, Welcome to the forum!!

First of all, get rid of the spring tensioner & make it a solid tensioner!! (the spring will still let the chain bounce around at high speed).

Second, you might try using a #410H chain for the right side of the jackshaft.
#410H chain is thinner & still plenty strong enough to use.
 

nonya0992

New Member
Dec 29, 2018
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Hi, Welcome to the forum!!

First of all, get rid of the spring tensioner & make it a solid tensioner!! (the spring will still let the chain bounce around at high speed).

Second, you might try using a #410H chain for the right side of the jackshaft.
#410H chain is thinner & still plenty strong enough to use.
Right now I dont have the means to make a solid tensioner. Its a pretty stout spring and its on the coasting side of the chain so it shouldnt move much. I found out about the 410 chain about 30 minutes ago and already ordered one along with a half link just in case. Maybe by then I can figure out a solid tension solution. I also found a picture online of a guy who made a spacer plate between the two chains. I rigged something up for testing purposes and we will see how it goes. Right now its a metal plate but ultimately it would be ideal to be plastic or vinyl. The plate goes in line with the lower part of the frame so the chain doesnt catch when it is in high gear. The driven chain also doesnt catch and will just skim it occasionally. Maybe once I get the 410 chain in then it will allow for more clearance.
 

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nonya0992

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Dec 29, 2018
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Well, the shifter kit is dead. I snapped the 415 chain I was using on the right side, twice. Bent a bracket, then stripped the one way bearing in the pedal assembly trying to start it. I was going to use a pull start but the shaft that the magnet mounts to is slightly bent and the inner part of the pull start hit the inside of the housing. Im going back to the single speed setup.
 

MacZulu

Member
Jul 3, 2015
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Vancouver
I just changed my set up to a 3 spd jackshaft set up, it is a pain. and I thought it would be awesome right off the bat, but I was a little surprised at first.the more I ride it, the more used to it I am getting. with just my 44T rag joint set up I was just WOT everywhere, there was a get on it and go feel. I am adapting to 3 spd and it is growing on me. I am also still breaking in a new engine, which complicates things a little.

I can't remember when or where I read that pull starts were a bad thing on shift kit engines. I know my new engine takes quite the kick to start it, waaaaay harder than the single speed where the back tire does all the work for you. and shifting between one block stops isn't worth the effort, so I travel a little slower on those types of streets. but getting on a good stretch of road and shifting through the gears with a tach is fun and I'm still not at full power.

replace the broken parts and read up some more, and maybe try again when you feel like it. I am running my normal 415 engine chain let side and 2 410's right side. with no jump stop installed. but setting up 3 chains is real fun...

I am still tweaking things on it, but its coming along
 
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nonya0992

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Dec 29, 2018
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Doing some more investigations I found that I didnt strip the pedal assembly bearing, I stripped the threads between the crank and the bearing itself. Didnt have any issues putting the two together som Im curious how it stripped out.

When it was working it was pretty cool to be able to shift gears on a bike like that and made the engine rpms at a lower more manageable level.

But Im pretty sure Im done with the shifter kit. Being in Korea limits what I can do since I am away from my shop and proper tools back home.
 

nonya0992

New Member
Dec 29, 2018
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Is there any place that once could go to buy just parts of a shifter kit and not have to spend all that money on and entire kit just to replace a few parts?
 

MacZulu

Member
Jul 3, 2015
171
12
18
Vancouver
Any chance some mechanics or machinist on your base might help fab up replacements?

The bracket parts would be hard to buy themselves, i bought 4 bearings for $16 CAD from amazon.