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techtalk:ref:svcproc10 [2019/01/09 02:49] ixl2relax ↷ Page name changed from techtalk:ref:notes303 to techtalk:ref:svcproc01 |
techtalk:ref:svcproc10 [2019/01/09 03:03] ixl2relax ↷ Links adapted because of a move operation |
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| ==== 1957-Early 1982 Mainshaft Thrust Washer Roll Pin ==== | ==== 1957-Early 1982 Mainshaft Thrust Washer Roll Pin ==== | ||
| - | {{techtalk:ref:notes:roll_pin_hole_by_mosey.jpg?direct|}} ((photo by Mosey of the XLFORUM http://xlforum.net/forums/showthread.php?t=2009441&highlight=trans)) | + | {{techtalk:ref:svcproc:roll_pin_hole_by_mosey.jpg?direct|}} ((photo by Mosey of the XLFORUM http://xlforum.net/forums/showthread.php?t=2009441&highlight=trans)) |
| A roll pin is installed at the twelve o'clock position over the mainshaft hole to keep the spacers from spinning. The spacers on the end of the mainshaft have a tab that would hit the roll pin and lock in. | A roll pin is installed at the twelve o'clock position over the mainshaft hole to keep the spacers from spinning. The spacers on the end of the mainshaft have a tab that would hit the roll pin and lock in. | ||
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| ==== Countershaft Endplay ==== | ==== Countershaft Endplay ==== | ||
| - | |{{techtalk:ref:notes:countershaft_endplay_1_by_ferrous_head.jpg?direct&300|}}|{{techtalk:ref:notes:countershaft_endplay_2_by_ferrous_head.jpg?direct&300|}}|{{techtalk:ref:notes:countershaft_endplay_3_by_ferrous_head.jpg?direct&300|}}| | + | |{{techtalk:ref:svcproc:countershaft_endplay_1_by_ferrous_head.jpg?direct&300|}}|{{techtalk:ref:svcproc:countershaft_endplay_2_by_ferrous_head.jpg?direct&300|}}|{{techtalk:ref:svcproc:countershaft_endplay_3_by_ferrous_head.jpg?direct&300|}}| |
| | Mock setup: obviously the box is not in the cases \\ where it needs to be to do the job. But easier for \\ pictures. NOTE ! You may be able to see the dial \\ indicator stem is actually sitting on the countershaft \\ bearing outer race - it needs to be sitting on the end \\ of the shaft here, not on the bearing. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))|A closer shot and here you can see the wire (bent) that \\ is used to push and pull on the countershaft. The dial \\ indicator is centered on zero of course before you start \\ pushing and pulling. You can then read the endplay \\ directly from the dial indicator. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))|This is the dial indicator mounted on the alloy spacer \\ with the bolt through it. The bolt just screws into the \\ bottom tranny case mount hole on the left case half \\ with the tranny sitting correctly in the engine. You will \\ also need a selection of thrust washers to actually \\ adjust the endplay to get it where it needs to be. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))| | | Mock setup: obviously the box is not in the cases \\ where it needs to be to do the job. But easier for \\ pictures. NOTE ! You may be able to see the dial \\ indicator stem is actually sitting on the countershaft \\ bearing outer race - it needs to be sitting on the end \\ of the shaft here, not on the bearing. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))|A closer shot and here you can see the wire (bent) that \\ is used to push and pull on the countershaft. The dial \\ indicator is centered on zero of course before you start \\ pushing and pulling. You can then read the endplay \\ directly from the dial indicator. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))|This is the dial indicator mounted on the alloy spacer \\ with the bolt through it. The bolt just screws into the \\ bottom tranny case mount hole on the left case half \\ with the tranny sitting correctly in the engine. You will \\ also need a selection of thrust washers to actually \\ adjust the endplay to get it where it needs to be. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))| | ||
| - | |{{:techtalk:ref:notes:countershaft_endplay_4_by_ferrous_head.jpg?direct&300|}}| | + | |{{techtalk:ref:svcproc:countershaft_endplay_4_by_ferrous_head.jpg?direct&300|}}| |
| |The really important bit - the bent wire. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))| | |The really important bit - the bent wire. ((Photo and article by Ferrous Head of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586&page=6))| | ||
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| * A cross section view of the right crankcase at the countershaft boss. | * A cross section view of the right crankcase at the countershaft boss. | ||
| * The 52-53 is the 1st iteration of the design. Each after that is noted as to the upgrade. | * The 52-53 is the 1st iteration of the design. Each after that is noted as to the upgrade. | ||
| - | {{techtalk:ref:notes:trans_case_fix_1_by_dr_dick.jpg?direct&600|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:trans_case_fix_1_by_dr_dick.jpg?direct&600|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| Line 220: | Line 220: | ||
| * And this is the most common mechanism failure (not the only failures, just the most common) | * And this is the most common mechanism failure (not the only failures, just the most common) | ||
| * The red is the broken areas. How long the countershaft continues to spin after this initial case failure determines how much worse the damage will become. | * The red is the broken areas. How long the countershaft continues to spin after this initial case failure determines how much worse the damage will become. | ||
| - | {{techtalk:ref:notes:trans_case_fix_2_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:trans_case_fix_2_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| * The 73-76 cases are almost immune to this failure. It's rare to see them welded up. They can survive all but the worst case scenario. The 77-79 cases were slightly thinner. They break more often but still are stronger than the 72< design. Then around 1980 you start seeing cases busted badly again. They must be cast of lower quality material. | * The 73-76 cases are almost immune to this failure. It's rare to see them welded up. They can survive all but the worst case scenario. The 77-79 cases were slightly thinner. They break more often but still are stronger than the 72< design. Then around 1980 you start seeing cases busted badly again. They must be cast of lower quality material. | ||
| Line 229: | Line 229: | ||
| * On Late 66>-72 cases this fix can be considered done. Early 66< cases are inherently weaker from the missing .125 fillet. | * On Late 66>-72 cases this fix can be considered done. Early 66< cases are inherently weaker from the missing .125 fillet. | ||
| * The reinforcement rings: | * The reinforcement rings: | ||
| - | {{techtalk:ref:notes:trans_case_fix_3_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:trans_case_fix_3_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| - | {{techtalk:ref:notes:trans_case_fix_4_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:trans_case_fix_4_by_dr_dick.jpg?direct|}} ((Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| * Doing the above is a big help and is advised but at times even with the ring installed, it will still fail as shown in the red pic. | * Doing the above is a big help and is advised but at times even with the ring installed, it will still fail as shown in the red pic. | ||
| * Optionally, you can go to the next level- you weld the ring so the ring becomes part of the case instead of part of the boss. | * Optionally, you can go to the next level- you weld the ring so the ring becomes part of the case instead of part of the boss. | ||
| - | {{techtalk:ref:notes:trans_case_fix_5_by_dr_dick.jpg?direct|}} ((Photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:trans_case_fix_5_by_dr_dick.jpg?direct|}} ((Photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| * Note that the welds are small enough that they can be removed to restore the original design. Some guys screw rings to the case with screws thru the .250 thick wall behind the ring instead of welding. | * Note that the welds are small enough that they can be removed to restore the original design. Some guys screw rings to the case with screws thru the .250 thick wall behind the ring instead of welding. | ||
| Line 272: | Line 272: | ||
| * For other cases, I've used alloy rings, with a slight vertical cut on the face to ensure the Torrington will receive enough oil... ((thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) | * For other cases, I've used alloy rings, with a slight vertical cut on the face to ensure the Torrington will receive enough oil... ((thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) | ||
| - | {{techtalk:ref:notes:sprocket_bore_mod_by_thefrenchowl.jpg?direct|}} ((photo by thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:sprocket_bore_mod_by_thefrenchowl.jpg?direct|}} ((photo by thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) |
| * For most guys with a small garage, welding and machining is not an option and can take the non welding route most of the time as far as cases are concerned if welding is not strictly necessary and can be avoided. | * For most guys with a small garage, welding and machining is not an option and can take the non welding route most of the time as far as cases are concerned if welding is not strictly necessary and can be avoided. | ||
| * A nicely light press fit helped with stud loctite will go a long way!!! My above mod on my KHK cases was done some 15 years ago at least, hasn't move a yota, suits me fine!!! But then, the crack was minimal and caught in good time before it got worse... ((thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) | * A nicely light press fit helped with stud loctite will go a long way!!! My above mod on my KHK cases was done some 15 years ago at least, hasn't move a yota, suits me fine!!! But then, the crack was minimal and caught in good time before it got worse... ((thefrenchowl http://xlforum.net/forums/showthread.php?t=1512080)) | ||
| Line 307: | Line 307: | ||
| * On L66-72 it will lead to bearing failure. | * On L66-72 it will lead to bearing failure. | ||
| * On 54-early 66 unwelded rings this may be seen upon bearing replacement where the yellow is the bearing: | * On 54-early 66 unwelded rings this may be seen upon bearing replacement where the yellow is the bearing: | ||
| - | {{techtalk:ref:notes:bearing_bore_failure_by_dr_dick.jpg?direct|}} (( Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) | + | {{techtalk:ref:svcproc:bearing_bore_failure_by_dr_dick.jpg?direct|}} (( Illustration by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080)) |
| * Its hard, if not impossible, to get a measurement off the case boss O.D. I made up a set of gauging rings in .001 bore increment steps to find boss O.D. These gauging rings need to be long enough to be manipulated inside case. | * Its hard, if not impossible, to get a measurement off the case boss O.D. I made up a set of gauging rings in .001 bore increment steps to find boss O.D. These gauging rings need to be long enough to be manipulated inside case. | ||
| Line 328: | Line 328: | ||
| * Not so bad. Of the different kinds of damage this is the easiest to repair and in my opinion results in a phenomenally tuff crankcase. I never seen one fail after what I'm going to describe. I have personally done this procedure many times. My '60ch 72" is done like this. I hammer the hell out of that bike. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * Not so bad. Of the different kinds of damage this is the easiest to repair and in my opinion results in a phenomenally tuff crankcase. I never seen one fail after what I'm going to describe. I have personally done this procedure many times. My '60ch 72" is done like this. I hammer the hell out of that bike. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| - | {{techtalk:ref:notes:cracked_boss_right_case_by_bobber58.jpg?direct|}} ((photo by bobber58 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | + | {{techtalk:ref:svcproc:cracked_boss_right_case_by_bobber58.jpg?direct|}} ((photo by bobber58 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) |
| * But 1st: | * But 1st: | ||
| * When you weld you WILL get warpage that accompanies that welding. The more you weld the more warpage you will get. The underlying cause for this is: as metal changes temperature, it changes in size. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * When you weld you WILL get warpage that accompanies that welding. The more you weld the more warpage you will get. The underlying cause for this is: as metal changes temperature, it changes in size. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| Line 338: | Line 338: | ||
| * What you got now. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * What you got now. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| - | {{techtalk:ref:notes:case_bore_fix_1_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | + | {{techtalk:ref:svcproc:case_bore_fix_1_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) |
| * The details: Ring 6061-T6 alum, filler rod 4043 alum. | * The details: Ring 6061-T6 alum, filler rod 4043 alum. | ||
| * The 1.75 in. case bore will keep the weld away from the lower kicker cover bolt and dowel. It will also leave a 1/8 in. wide deck in the case that gives you a set height to work from. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * The 1.75 in. case bore will keep the weld away from the lower kicker cover bolt and dowel. It will also leave a 1/8 in. wide deck in the case that gives you a set height to work from. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| - | {{techtalk:ref:notes:case_bore_fix_2_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | + | {{techtalk:ref:svcproc:case_bore_fix_2_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) |
| * This is the finished product: ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * This is the finished product: ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| - | {{techtalk:ref:notes:case_bore_fix_3_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | + | {{techtalk:ref:svcproc:case_bore_fix_3_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) |
| * This welding also needs to be done before reshooting bores. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * This welding also needs to be done before reshooting bores. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
| - | {{techtalk:ref:notes:trans_case_fix_5_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | + | {{techtalk:ref:svcproc:trans_case_fix_5_by_dr_dick.jpg?direct|}} ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) |
| * This procedure results in no perceptible warpage at the case parting seams. this cant be said when the case corner is blown apart and a new cast corner piece is welded in. Obviously the outcome is dependent on quality of workmanship. When doing this work the time is right for making sure your door fits correct too. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | * This procedure results in no perceptible warpage at the case parting seams. this cant be said when the case corner is blown apart and a new cast corner piece is welded in. Obviously the outcome is dependent on quality of workmanship. When doing this work the time is right for making sure your door fits correct too. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1512080&page=3)) | ||
