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My 89 1500 has just started making an intermittent rattling
noise and having read some of the other posts, I think I have the fourth gear problem. Can anyone tell me if this problem needs to be fixed urgently, or can I leave it for a while before fixing it?
Is the problem going to cause further damage if I keep riding it for the next couple of weeks?
The reason I ask is, I work for myself and use my bike as my primary mode of transport, so taking it off the road in order to fix it is a big problem ( no work, no money!).

Thanks

Trevor
 

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Trevor, I think the 4th gear problem only occurred with the 1994 models. If you tell us a bit more (like does the noise only happen in 4th etc), I'm sure some of the gurus will be able to advise you better. Also, don't forget that out of balance carbs can cause an engine rattle on the 1500, usually under load and sharp acceleration.
 

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Yes Trevor, let us know some more. The common cause for rattling on the 1500 is worn alternator bearings or worn rubber drive from the alternator/engine.
 
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Hey Trevor :waving: Your welcome to the forum all the way from Newbridge Co.Kildare. :clapper:

:leprechaun: :18red: :leprechaun:
 

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Hi guys,

The symptoms are interrmittent, and only occured when warming the bike up, in neutral and on the centre stand. I found that there was a very sharp rattling/grating noise, which sounded as though it was coming from the front of the bike. This would dissapear, however lifting the bike off of the centre stand would cause it to occur again. Once off the centre stand I would hear it whilst the bike was idling and pulling in the clutch made no difference. When driving the bike and accelerating through the gears , this problem dissapeared and only showed up when decelerating in the lower gears and backing off the throttle. In third gear the noise is a lot less and is absent completely in fourth and fifth gear.

So, have you any ideas as to the cause and more importantly, will it cause further damage to the engine if I keep riding?

Thanks

Trevor
 

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They were last changed four years ago when I got the bike.
Since I have had it I have put about 60K km on it and was going to change them at 75K. I will take a look and get back to you.

Cheers

Trevor
 

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I think its tensioners too. They would come under load when you decelerate with the gears and the engine revs up. If it's doing it on the center stand as well in neutral then the gears are not moving (only the mainshaft) so it won't be a gear noise. Also consider the water pump. Its easy to remove and check for roughness on the 1500.
 

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Also inspect for loose exhaust parts such as the chrome covers over the pipes, clamps and anything that is bolted to the engine. I periodically go over every nut and bolt onmy bike just to be sure they're tight. A loose plastic cover on the sides and around the fairings will also rattle with engine oscillation. The belly pan on the 1500's is metal and does vibrate if it's loose. It will drive you crazy looking for it, but it's usually an easy fix. Have someon assist you controlling the engine while you crawl around and listen. Do this in a garage or somewhere that will prevent any ouside noise sources.
 

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Guys,

Iv'e checked the belt tensioners and they are ok.
The belts look good as well, but I'll probably change them
whilst I have the opportunity.
If the problem is with the water pump, I would have expected to see signs of leakage from around the bearings etc., but it all seems to look ok and I have not seen any puddles under the bike.
 

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Trevor, Yes you have the fourth gear shift fork problem. My 89 1500 is at this moment being repaired. The symptoms you describe are / were exactly the same as I had. This is an expensive repair, which involves removing the engine and splitting the crankcase for access to the transmission parts. Apparently this isa designfault which has never been recognised by Honda. I have a specialist in Altrincham carrying out this work for me...cost £1200.

Joe
 

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I'd take the water pump out firt before paying for the engine to be pulled for the gearbox to be checked (if the moise isi still there when you pull in the clutch then I doubt it the gears). Spin the water pump impeller by hand to check for roughness, the seal won't leak until there is a good bit of loose play.
 

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Keith Cross from the GWOCGBwas good enough to sendme the info on the 4th gear repair part numbers for the 1994 model year, some of you may find it useful. Keith wrote;

Recently I have been rebuilding
the odd 1500 gearbox or 5 and when the last lot of spare parts came for a
1994 model, some modified parts were sent. These parts were all for the
mainshaft and consisted of:

4th gear
4th/5th gear shifter
Collar (that the above fit onto)

The new part number is 23010-MAM-305 and come as a kit. I believe that if
you order one part you get all 3 (Honda subsidy?)

Unfortunatly the kit does'nt include the selector fork also needed.
 

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Wingnut, Your so right again.
My USED 1990SE 73,250 miles had the same problem making the same noise. The noise was coming from the back of the engine. It sound like a gear rubbing on the case of the transmission. What made me think I had a real problem was the lack of 4th gear. The noise was only in neutral and would change when I would lean the bike one way or the other. I lived with this for 3.000 miles. The last ride was when I shifted to 4th and nothing was there. Shifted to 5th all was fine. Drove the bike back home anda friend who isa great Honda Mechanic took it apart. I heard there was a problem with 4th gear in some Goldwings. We removed the engine, split the case, opened the transmission and found the problem. Fourth and Fifth gear fork was badly bent and not letting the collar and gear in gauge. The noise was from the bent fork letting the sliding gear hitting into the collar of forth gear. It was partly engaged and making the noise. Leaning the bile would let the gear move and the noise would change.Everything in the engine looked as if it was new. Called the local Honda shop and they new of the problem with forth gear. They said under a load the slider collar would try to disengage and over a peiod of can and would bend the shifting fork. I think this is what happen to mine. They have the replacement parts in stock and it is a New and Improved kit. The new gear and collar shaft are much heaver and have more surface to engage the gears. They look much heavier duty. Everything fits great and work's great now we got it all back together. Runs and drives like new no noise and shifts like new.
Now the bad part:
About 25 hours of labor $850.00 for parts (4th gear kit, seals, gasket kit, oil) total repair cost $1,350.00.

Good Luck !
buswayne
 

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Carl
This is where my questions to you in your 1st post are leading to.
 
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