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techtalk:ref:tools107 [2019/01/20 01:40] hippysmack xlforum |
techtalk:ref:tools107 [2024/01/23 03:43] (current) hippysmack [Bushing Installation] |
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| [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{ :techtalk:gototechnicalmenu.jpg|}}]] | ||
| ====== REF: Tools - 107 ====== | ====== REF: Tools - 107 ====== | ||
| - | ====== Cam Bushing Removal Tools ====== | + | ====== Cam Bushing Measuring / Removal / Installation Tools ====== |
| - | ===== Bushing Removal ===== | + | \\ |
| + | ====== #2 Cam Gear Press ====== | ||
| + | A gear puller shaft attached to a bearing separator for pressing the gear on #2 cam. \\ | ||
| + | |Gear press for #2 cam gear. ((photo by jstoll of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-styles/sportster-motorcycle-project/182089-jak-stolls-xl1200f-frankenbike?t=1961921))| | ||
| + | |{{:techtalk:ref:tools:gear_press_for_2_cam_by_jstoll.jpg?direct&250|}}| | ||
| + | ====== Measuring the Bushings ====== | ||
| + | | Measuring Cam Bushinhgs. ((photos by AussieGazza of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/87710-aussiegazzas-rebuild/page5?t=692835&page=5)) ||| | ||
| + | |{{:techtalk:ref:tools:measuring_cam_bushings_1_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:ref:tools:measuring_cam_bushings_2_by_aussiegazza.jpg?direct&300|}}|{{:techtalk:ref:tools:measuring_cam_bushings_3_by_aussiegazza.jpg?direct&300|}}| | ||
| + | ====== Bushing Removal ====== | ||
| * You can buy different brands but this is basically a slide hammer with an expandable collet. \\ See also [[techtalk:ref:engmech01g|Cam Bushing Removal]] in the Sportsterpedia. | * You can buy different brands but this is basically a slide hammer with an expandable collet. \\ See also [[techtalk:ref:engmech01g|Cam Bushing Removal]] in the Sportsterpedia. | ||
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| |{{:techtalk:ref:tools:98_1200_cam_bushing_removal_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_1_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ref:tools:98_1200_cam_bushing_removal_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_2_by_hippysmack.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_1_by_hippysmack.jpg?direct&300|}}| | ||
| - | |Also check local auto parts stores for a pilot bearing puller. \\ This works basically the same as the slide hammer except it pulls the bushings out instead of knocking them out. ((photos by 62 Ironhead of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=2))||| | + | |Check local auto parts stores for a pilot bearing puller. ((photo by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2))| |
| - | |{{:techtalk:ref:tools:pilot_bearing_puller_1_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_2_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_3_by_62_ironhead.jpg?direct&300|}}| | + | |{{:techtalk:ref:tools:pilot_bearing_puller_1_by_62_ironhead.jpg?direct&300|}}| |
| + | |||
| + | |This works basically like the slide hammer except it pulls the bushings out instead of knocking them out. ((photos by 62 Ironhead of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2)) ||For smaller bushings, grind the back of the jaws a \\ little so they close more to fit the smaller space. ((photo by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page7?t=1793066&page=7))| | ||
| + | |{{:techtalk:ref:tools:pilot_bearing_puller_2_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_3_by_62_ironhead.jpg?direct&300|}}|{{:techtalk:ref:tools:pilot_bearing_puller_by_decman.jpg?direct&300|}}| | ||
| + | |||
| + | **Homemade bushing remover**: \\ | ||
| + | The puller is made from 1" ID black pipe and 1/2"-13 threaded rod. You tap the flex head-puller head through the cam bearing. \\ | ||
| + | The little nub puller with a collar that you knock into the bearing is made from 3/4" rod. Then screw the rod into the head to tighten the jaws. \\ | ||
| + | Then place the collar over the rod and nut to start the pulling. \\ | ||
| + | |||
| + | 4 grooves were cut into the end for flex / compression to push through the bearing. \\ | ||
| + | Then it was center drilled 7/16" and tapped 1/2"-13 and the slots were cut with a 3/16" end mill. \\ | ||
| + | The threaded rod causes outward pressure on the jaws of the head when pulled. ((photos by fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight)) | ||
| + | \\ | ||
| + | |{{:techtalk:ref:tools:homemade_cam_bushing_tools_1_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_2_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_4_by_fergerburger.jpg?direct&300|}}| | ||
| + | |||
| + | |{{:techtalk:ref:tools:homemade_cam_bushing_tools_5_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_6_by_fergerburger.jpg?direct&300|}}|{{:techtalk:ref:tools:homemade_cam_bushing_tools_7_by_fergerburger.jpg?direct&300|}}| | ||
| + | |||
| + | ====== Bushing Installation ====== | ||
| + | These are typically knocked in with a commercially available long rod and a hammer. \\ | ||
| + | Below are a couple homemade tools for installing the bushings. A knocking rod and a compression plate. \\ | ||
| + | |||
| + | The knocker rod is made from 1" aluminum bar stock with a .030" shoulder to recess into the bearing, .030" into the case. ((fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight?t=1349714)) \\ | ||
| + | |||
| + | The compression plate is made from a scrap steel plate. The bolts screw in to push the bushings in place. See the [[techtalk:ref:tools107#reverse_engineered_cam_bushing_installer|build pics]] below by Hippysmack. \\ | ||
| + | |||
| + | {{:techtalk:ref:tools:homemade_cam_bushing_tools_3_by_fergerburger.jpg?direct&300|}} ((photo by fergerburger of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129325-cam-chest-tools-made-tonight?t=1349714)) {{techtalk:ref:tools:cam_bushing_installer_41_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{techtalk:ref:tools:cam_bushing_installer_39_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
| ===== Modified Cover for Reaming ===== | ===== Modified Cover for Reaming ===== | ||
| - | | Modified cam covers for reaming ((left photo by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753)) ((right photo by Hippysmack)) || | + | | Modified cam covers for reaming ((left photo by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page6?postid=5016753#post3644788)) ((right photo by Hippysmack)) || |
| |{{:techtalk:ref:tools:modified_cam_bushing_cover_for_reaming_by_decman.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_4_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:ref:tools:modified_cam_bushing_cover_for_reaming_by_decman.jpg?direct&300|}}|{{techtalk:ref:tools:cam_bushing_installer_4_by_hippysmack.jpg?direct&300|}}| | ||
| - | |The bushing holes were drilled thru for -access into and thru the cover bushings to the case bushings. ((photos by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753))|| | + | |The bushing holes were drilled thru for -access into and thru the cover bushings to the case bushings. ((photos by decman of the XLFORUM https://www.xlforum.net/forum/general-area/off-topic-general-discussion/166860-this-week-in-my-shop/page6?postid=5016753#post3644788))|| |
| |{{:techtalk:ref:tools:modified_cam_bushing_cover_2_for_reaming_by_decman.jpg?direct&300|}}|{{:techtalk:ref:tools:modified_cam_bushing_cover_3_for_reaming_by_decman.jpg?direct&300|}}| | |{{:techtalk:ref:tools:modified_cam_bushing_cover_2_for_reaming_by_decman.jpg?direct&300|}}|{{:techtalk:ref:tools:modified_cam_bushing_cover_3_for_reaming_by_decman.jpg?direct&300|}}| | ||
| - | ===== Reamers ===== | ||
| - | **Cam cover bushings**: \\ | ||
| - | 9/16" for the pinion shaft bushing. \\ | ||
| - | 1-1/8" for #2 cam bushing. \\ | ||
| - | 11/16" for #1, #3 and #4 cam bushings. \\ | ||
| - | **Case bushings**: \\ | + | ===== Reamers ===== |
| - | 11/16" for #1-#4 cam bushings. \\ | + | See [[techtalk:ref:tools147#cam_bushing_reamers|Cam Bushing Reamers]] in the Sportsterpedia. \\ |
| - | + | ||
| - | | Cam bushing reamers ((photo by decman of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5016753)) | | + | |
| - | |{{:techtalk:ref:tools:cam_bushing_reamers_by_decman.jpg?direct&300|}}| | + | |
| ====== Reverse Engineered Cam Bushing Installer ====== | ====== Reverse Engineered Cam Bushing Installer ====== | ||
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| I decided to make my own bushing installation tool since I have checked with the MOCO in three states and nobody has the one mentioned in the FSM for sale. A bushing hammer would have worked fine but I didn't want to beat the cam bushings in my engine. Besides, I wanted to use the shop. The plan is to make an installer, press the bushings in with it and ream the bushings thru a spare and molested cam cover. I'm doing this backwards from the FSM. Your suppose to ream the bushings to exactly 11/16" at a right angle, place the cover on the case half (which has been split from the left case half) and then ream through from the case half into the cam cover with a pilot reamer. I have a reamer that is 11/16" dia from one end to the other and the cutting blades are over 3" long. | I decided to make my own bushing installation tool since I have checked with the MOCO in three states and nobody has the one mentioned in the FSM for sale. A bushing hammer would have worked fine but I didn't want to beat the cam bushings in my engine. Besides, I wanted to use the shop. The plan is to make an installer, press the bushings in with it and ream the bushings thru a spare and molested cam cover. I'm doing this backwards from the FSM. Your suppose to ream the bushings to exactly 11/16" at a right angle, place the cover on the case half (which has been split from the left case half) and then ream through from the case half into the cam cover with a pilot reamer. I have a reamer that is 11/16" dia from one end to the other and the cutting blades are over 3" long. | ||
| - | |||
| * My cam bushings turned out to be .005" out of service limit in the right case half. So, I yanked them out with the HF tool above. | * My cam bushings turned out to be .005" out of service limit in the right case half. So, I yanked them out with the HF tool above. | ||
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| |{{techtalk:ref:tools:cam_bushing_installer_54_by_hippysmack.jpg?direct&300|}}| | |{{techtalk:ref:tools:cam_bushing_installer_54_by_hippysmack.jpg?direct&300|}}| | ||
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