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techtalk:ref:svcproc9a [2024/05/01 17:26] hippysmack ↷ Page name changed from techtalk:ref:svcproc9a to techtalk:ref:svcproc9g |
techtalk:ref:svcproc9a [2024/05/01 21:28] hippysmack [1965 XLCH Transmission Assembly] |
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| + | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
| + | ====== REF: Service Procedures 9A ====== | ||
| + | \\ | ||
| + | ====== 1965 XLCH Transmission Assembly ====== | ||
| + | Article by scottericsonon of the XLForum ((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/85677-transmission-assembly-tutorial-w-pics?t=657134)) \\ | ||
| + | A used transmission bought from Ebay was disassembled and the parts swapped over to the original trapdoor. \\ | ||
| + | The used transmission had all Andrews gears as well as the mainshaft and countershaft. \\ | ||
| + | I put new main and countershaft bearings in my trapdoor so I could reuse it so I know everything will line up with my case. \\ | ||
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| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_andrews_gears_1_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_andrews_gears_2_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_andrews_gears_3_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_andrews_gears_4_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_andrews_gears_5_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Empty trapdoor. \\ | ||
| + | I should note that while it was empty, I DID punch out the countershaft oiler plug so I can set endplay later. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_trapdoor_1_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Clutch gear with new bearing loaded into trap. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_trapdoor_2_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_trapdoor_3_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Mainshaft loaded in. You WILL have to pull it back apart again but I wanted to get the trans loaded just so I could see how everything fit together before I put the shift forks in. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_mainshaft_loaded_1_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_mainshaft_loaded_2_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | (L) Countershaft in too. Spin it a couple times and slide all the gears around to see that everything operates free. \\ | ||
| + | Then tear it back down and then start reassembly WITH the shifter forks. \\ | ||
| + | (R) Slip your C/S fork around it's gear (3rd) and get the finger roller in the cam. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_countershaft_loaded_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic1_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | (L) Then get your mainshaft fork in position and slip it's gear (2nd) in from the side. \\ | ||
| + | (R) Slip your mainshaft into it's home thru 2nd and clutch gears and put low back on the countershaft not forgetting your washers (74 and up have 2). \\ | ||
| + | Then go ahead and slide your fork shaft in and run her thru the gears a handful of times. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic2_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic3_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Here is the transmission completely assembled to measure clearances on the gears. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic4_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic5_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | After you get it all together, run it back and forth thru the gears a handfull of times. \\ | ||
| + | This is to get everything settled into where it's supposed to be (plus it's neat to see how everything works together) \\ | ||
| + | Put it in neutral to measure your clearances. \\ | ||
| + | (R) Measure spacing between C/S low and C/S 3rd like this. You want .038"-.058" here. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic6_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic7_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | (L) You adjust clearance with these washers. \\ | ||
| + | (R) Then measure between the dogs on C/S 3rd the face of C/S 2nd like this. \\ | ||
| + | You want .038"-.058" here as well. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic8_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic9_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | (L) Then check between M/S 2nd and M/S clutch gear .043"-.083" of clearance. \\ | ||
| + | (R) M/S 2nd and M/S 3rd .043"-.083" here as well. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic10_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic11_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Checking C/S clearance. I have .006" \\ | ||
| + | Don't mind my redneck setup. I'm just a poor bastard trying to do shit on a budget. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic12_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic13_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic14_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic15_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Putting some pressure on the M/S to emulate the clutch being there and engaged. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic16_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic17_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | (L) Checking the M/S endplay. I have .006" \\ | ||
| + | (R) Grab your shift shaft and slide it into its home making sure to have it level so it will go into it's pocket on the trans. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic18_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic19_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | Grab your M/S rollers making sure to COUNT THEM so you know you have all 23. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic20_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] | ||
