Differences

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--- techtalk:ref:svcproc9 [2024/05/01 00:32] – [Sub-Documents] hippysmack
+++ techtalk:ref:svcproc9 [2025/08/14 16:13] (current) – [Voices of Reason] hippysmack
@@ Line 22: / Line 22: @@
   * My '78 used to pop out of second gear when accelerating. I finally removed the trans and discovered a worn shifter fork, bad shimming and a cam with a worn spot. Repaired the cam, bought new forks and replaced all the gears and shafts with Andrews parts. Gearbox now shifts like butter and has no false neutrals. I shimmed everything to perfection and it was worth every penny to have good Andrews parts in there. (ericfreeman)
   * The longer you run it, the more damage will be done. Tear it down before you tear up. (ryder rick)
   * Nothing wrong with taking your time (inspecting/repairing). Treat it as if you are working on a precision instrument. Because it is! (doodah man)
+  * Nothing in this post is ill spirited. It's straight talk between men. My hope is to help you turn a corner so you can actually fix your trans and clutch. \\ No one on this board can fix your bike because we can't touch it. It takes hands to build machines. Your hands in this case. Hands are useless unless they are given accurate instructions. Those instructions dont come from the internet, they come from your head. All we can do is fill in the mental gaps. It's up to you to lay your own foundation. We can't do it for you. To that end, you need to slow down. Pictures of trans parts and pictures of naked women are equivalent. They are fun to see but posting them won't teach you how to service them. You personally gotta get between the sheets. If you are not sure what this or that parts are or how they are related, you're not sure because you havent studied it. You have to get the Factory Service and Parts Manuals and read them 1st. And read them as you work. All these parts have part numbers. From those part numbers, others will know what you are talking about. If you don't make yourself clear when asking questions, no one will take the time to unravel your cryptic posts. It is your bike and your trans job--- the common denominator is you! If your trans came out in pieces------- it didn't have to if you did your research. You need to self educate. Some self-education will keep that trans in one pc. If you don't rectify your thought and work processes concerning mechanical systems, you will be forever lost in front of the workbench. The manual says- assm the trans on the bench and teach yourself how the power flows thru it, and how shifting from gear to gear is accomplished. Then it says no trans building can be accomplished without that done first. You NEED to do this. You also need to identify each part and KNOW where it goes on final assembly. Put your due diligence in on the workbench then on the keyboard. That is a foundation of getting that diligence into your driveline. The most important tool your going to need isn't in your toolbox. It's between your ears. (Dr Dick)
-====== Gear Inspection ======
-===== Sub-Documents =====
+====== Removing / Installing the Transmission ======
-  * [[techtalk:ref:svcproc9a|Gear Dog Damage: Inspection and Causes]]
+==== Sub-Documents ====
-  * [[techtalk:ref:svcproc9e|Clutch Gear Conversion - an answer to the obsolete 900 c-ratio]]
+  * [[techtalk:ref:svcproc9a|1975 XLCH Transmission Assembly]]
+====== Inspections ======
+A good way to get familiar with the transmission and how it works (after removal from the case) is to put the assembled transmission on the bench or even better in a vice, spin the clutch gear and shift through the gears and watch how it all works together. Plus it's neat to watch. ((doodah man of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/193234-%C2%9168-xlch-transmission)) \\
+See the GEAR section below and click on Gear Dog Damage: Inspection and Causes in the sub documents for drawings and an animation of transmission gear action. That will also help understanding how the transmission works. \\
+===== Gears =====
+==== Sub-Documents ====
+  * [[techtalk:ref:svcproc9g|Gear Dog Damage: Inspection and Causes]]
+  * [[techtalk:ref:svcproc9h|Clutch Gear Conversion - an answer to the obsolete 900 c-ratio]]
 With some of these parts, finding imperfections and cracks requires more than just glancing at them for obvouos damage. \\
@@ Line 34: / Line 43: @@
 {{:techtalk:ref:svcproc:transmission_gear_inspection_pic_by_dirtycory.jpg?direct&600|}} ((photo by DirtyCory of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page20?t=1297584&page=26)) \\
-===== Cracks =====
+==== Cracks ====
 Any cracks found in a gear's teeth or body and the gear needs to be replaced. \\
 Some cracks are obvious and some are hard to see on a quick glance as shown below. \\
@@ Line 50: / Line 59: @@
 These gears have a habit of cracking on the ID were the cross section changes thickness. \\
 Cleaning with some 2000 grit emery revealed the crack better in the Left pic below. ((L photo by DirtyCory, R photos by DirtyCory and IronMick, compiled by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page17#post2849730)) \\
+If you look at them closely, you will see that the dog pockets are formed not machined. ((ryder rick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/189718-1982-ironhead-transmission-removal-w-pics/page2)) They have sharp corners and some of the corners are adjacent to the root of the gear tooth. Those sharp corners and the thin material create stress risers that encourage cracking. In contrast, look at the pockets on the same Andrews gear, it is machined and the corners are round. \\
 {{:techtalk:ref:svcproc:4_speed_trans_gear_inspection-_ms_3rd_cracked_id_by_dirtycory.jpg?direct&400|}} {{:techtalk:ref:svcproc:4_speed_trans_gear_inspection-_ms_3rd_cracked_and_broken_pics_by_dirtycory_and_ironmick.jpg?direct&400|}}
-===== Teeth Wear =====
+==== Teeth Wear ====
 On bikes with seroius power output, replacing 3rd gear sets is a seasonal requirement. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page19#post2849730)) \\
 {{:techtalk:ref:svcproc:4_speed_trans_gear_inspection-_cs_3rd_worn_teeth_by_dr_dick.jpg?direct&400|}} ((photos by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page19#post2849730, labeled and composed by Hippysmack)) \\
-====== Repairs ======
+===== Repairs =====
 In terms of repairs; the first thing you must make 100% sure of is that there is no damage whatsoever to the case boss. ((Chuckthebeatertruck of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/204280-trans-door/page3)) This means you may need to dye penetrate it. Most common radiating cracks seem to appear at 7:30 and 4:30 with these types of breaks. \\
 Also carefully examine the needle bearing in the CS boss in the case. NO rollers can be distorted or hang up. Carefully check it and make sure it moves freely. If you reuse the 4th MS (clutch) gear, make sure the needle there didn't take any unusual force and flat spot or distort. \\
@@ Line 70: / Line 80: @@
 And yes, strokers can destroy parts without trying. You don't have to beat on it to break it. There's massive amounts of torque available in a stroker from idle on up. If you can wheel stand the bike with a clutch dump in 2nd (you can!) then you can get an idea of just how much force the parts have to deal with. It gets way, way worse the bigger you go. Strokers can be an expensive addiction but also a very sweet ride once you sort this stuff.
+==== Replacing Gears ====
-===== Replacing Gears =====
 Dr Dick's rust covered opinion on what the order of Andrews upgrade should be if you got to do it bit by bit: \\
 The first 3 are way more important than the last. ((Dr Dick https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/127032-getting-this-78-back-to-the-way-it-should-be/page22#post2849730)) \\
@@ Line 85: / Line 94: @@
   * Countershaft 1st
-====== Shifter ======
+===== Shifter =====
-===== Sub Documents =====
+==== Sub Documents ====
-  * [[techtalk:ref:svcproc9g|How to Blueprint Your Shifter]]
+  * [[techtalk:ref:svcproc9l|How to Blueprint Your Shifter]]
-====== Transmission Case ======
+===== Transmission Case =====
-===== Sub-Documents =====
+==== Sub-Documents ====
   * [[techtalk:ref:svcproc9p|Trans Corner Reinforcement 1954-1972]]
@@ Line 99: / Line 108: @@
 {{:techtalk:ref:svcproc:4_speed_trans_gear_inspection-_broken_trans_case_1_by_paraord.jpg?direct&400|}} {{:techtalk:ref:svcproc:4_speed_trans_gear_inspection-_broken_trans_case_2_by_paraord.jpg?direct&400|}} \\
-====== Access Cover (trapdoor) ======
+===== Access Cover (trapdoor) =====
-===== Sub-Documents =====
+==== Sub-Documents ====
-  * [[techtalk:ref:svcproc9t|Transmission Access Door Alignment]]
+  * [[techtalk:ref:svcproc9u|Transmission Access Door Alignment]]
+Make sure the trough in the roof of the trans case that leads oil to the bearing isn't compromised. ((barefoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/193234-%C2%9168-xlch-transmission)) \\
+Another one-inna-million occurrence, but if you are the one, it's unpleasant. \\
 \\
 [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]]

Trace: • REF: Service Procedures 9

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