Differences

This shows you the differences between two versions of the page.

--- techtalk:ref:svcproc9 [2024/04/30 23:39]
hippysmack [Sub-Documents]
+++ techtalk:ref:svcproc9 [2024/05/02 22:36] (current)
hippysmack [Cracks]
@@ Line 24: / Line 24: @@
   * Nothing wrong with taking your time (inspecting/repairing). Treat it as if you are working on a precision instrument. Because it is! (doodah man)
-====== Gear Inspection ======
+====== Removing / Installing the Transmission ======
-===== Sub-Documents =====
+==== Sub-Documents ====
-  * [[techtalk:ref:svcproc9a|Gear Dog Damage: Inspection and Causes]]
+  * [[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 33: / Line 42: @@
 {{: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 49: / Line 58: @@
 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 69: / Line 79: @@
 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 84: / Line 93: @@
   * 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 98: / Line 107: @@
 {{: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|}}]]