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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 [2024/05/02 00:54] 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|}} \\ | ||
| + | \\ | ||
| + | |||
| + | 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|}} \\ | ||
| + | \\ | ||
| + | |||
| + | (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|}} \\ | ||
| + | \\ | ||
| + | |||
| + | 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|}} \\ | ||
| + | \\ | ||
| + | |||
| + | Grab your M/S rollers making sure to COUNT THEM so you know you have all 23. \\ | ||
| + | Goo up the race and your C/S bearing and put all 23 rollers into place. \\ | ||
| + | MAKE SURE you put the flat washer in between the circlip and your bearing rollers!! | ||
| + | Did you check that it was there? Good...now check again. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic20_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic21_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
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| + | I greased up the rollers too so they would stick real well for me. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic22_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic23_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
| + | |||
| + | (L) Cross your fingers and slide the trans in. If it's in right it should ALMOST seat by hand. \\ | ||
| + | At least it should start on the dowels. If not, try wiggling it some. It will line up. \\ | ||
| + | Get your bolts in tightening each of them a little at a time so that your trapdoor goes in straight. \\ | ||
| + | Then when they're all tight, pull them one at a time and put a dab of Loctite on them. \\ | ||
| + | (R) Ok, next step. Grab all your kickstart stuff. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic24_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic25_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
| + | |||
| + | Slide the clutch shaft parts on with the collar first then the spring and the gear. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic26_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic27_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
| + | |||
| + | (L) I thought sure I took one with the starter crank gear too but can seem to find it now. \\ | ||
| + | ANYHOW install that it's tabbed lock washer and the nut tighten it up and fold over one of the lock tabs. \\ | ||
| + | Get your primary shoe in with one bolt just to hold it in place while you're putting the chain etc in. \\ | ||
| + | (I put a new plastic shoe on mine obviously) \\ | ||
| + | (R) Gather up your primary chain, crankshaft gear and clutch basket. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic28_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic29_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
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| + | (L) This would be an EXCELLENT time to test your kickstarter to make sure it functions correctly. \\ | ||
| + | Just put the clutch basket in place and hold in with your hand as your helper. \\ | ||
| + | (or yourself if you can reach) cranks the kick thru one cycle. \\ | ||
| + | Now get the basket back in along with the primary chain and crank sprocket. \\ | ||
| + | Get the crank nut and the clutch hub in tightened up (150 lb/ft ). \\ | ||
| + | Make sure you fold over a lock tab on your clutch hub nut. \\ | ||
| + | Crank gear nut is 1-1/4" while the clutch basket is 1-1/2". \\ | ||
| + | (R) gather up your clutch parts. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic30_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic31_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
| + | |||
| + | I had pulled the whole clutch as an assembly like this and left all the plates stacked while they were out. \\ | ||
| + | Made the install VERY easy as all I had to do was flip the stack over and put in pieces one at a time. \\ | ||
| + | Get the springs in the basket and grab your clutch release disk. \\ | ||
| + | Then get your spring compressor started and sneak the clutch release disk down behind it. \\ | ||
| + | (R) AS SOON AS you can get the locknuts started with 3 or 4 threads get them on there so the clutch isn't a loaded gun anymore. \\ | ||
| + | Go ahead and get those all tightened up and remove your spring compressor. \\ | ||
| + | It should be noted here that I have a 75 and as a result I have the spacers. \\ | ||
| + | If you have a different year (I think pre74), you don't want to just tighten up those nuts. \\ | ||
| + | There's a certain spacing they have to be at. \\ | ||
| + | Once your compressor is out of the way, slap the bolt in the lower hole of the primary adjuster. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic32_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic33_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
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| + | (L) Measure your primary chain slop and get that set to specs. \\ | ||
| + | Then go ahead and button up the rest of the adjuster making sure you double check slack after all your pieces are in and tight. \\ | ||
| + | (R) Ok, now let's move over to the right side of the bike for a bit. \\ | ||
| + | Grab your drive sprocket, a tabbed washer for that and it's nut and a 1-1/4" socket. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic34_by_scottericsonon.jpg?direct&400|}} {{:techtalk:ref:svcproc:1965_xlch_tranny_pic35_by_scottericsonon.jpg?direct&400|}} \\ | ||
| + | \\ | ||
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| + | Get that stuff on and tightened up remembering to fold the lock tabs over. \\ | ||
| + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic36_by_scottericsonon.jpg?direct&400|}} \\ | ||
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| + | [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] | ||
