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techtalk:ih:engmech02c [2020/08/25 02:08] hippysmack [Pining Bushings with a Set Screw] |
techtalk:ih:engmech02c [2023/12/20 16:21] (current) hippysmack |
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| ====== Selecting Bushings ====== | ====== Selecting Bushings ====== | ||
| - | The factory machine work on 70< cam covers is stellar. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904)) \\ | + | The factory machine work on 70< cam covers is stellar. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated?t=1717904)) \\ |
| Reproducing it at home is nearly impossible. Even in a full machine shop its very time consuming. \\ | Reproducing it at home is nearly impossible. Even in a full machine shop its very time consuming. \\ | ||
| A good (at home) job is possible if you know what your doing. \\ | A good (at home) job is possible if you know what your doing. \\ | ||
| Line 28: | Line 28: | ||
| See also [[techtalk:ref:tools107#cam_bushing_measuring_removal_installation_tools|Cam Bushing Measuring / Removal / Installation Tools]] in the Sportsterpedia for some ideas on tools you can use to remove the bushings. \\ | See also [[techtalk:ref:tools107#cam_bushing_measuring_removal_installation_tools|Cam Bushing Measuring / Removal / Installation Tools]] in the Sportsterpedia for some ideas on tools you can use to remove the bushings. \\ | ||
| - | |Check local auto parts stores for a pilot bearing puller. ((photo 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_1_by_62_ironhead.jpg?direct&300|}}| | ||
| ====== Installing Bushings ====== | ====== Installing Bushings ====== | ||
| - | * Bearing bronze into aluminum at room temp is a good matchup. There are no material shaving or galling problems associated with it. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3)) | + | * Bearing bronze into aluminum at room temp is a good matchup. There are no material shaving or galling problems associated with it. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3)) |
| * Just make sure there are no sharp edges on the bushing or cover bore. \\ You don't need to heat the case or freeze the bushing (unless you choose to). \\ The interference fit isn't great. One or both of the materials will flex under the interference. That adds up to the driving force never getting too great. \\ A note about heating aluminum; as temps rise, so does it's affinity for galling. | * Just make sure there are no sharp edges on the bushing or cover bore. \\ You don't need to heat the case or freeze the bushing (unless you choose to). \\ The interference fit isn't great. One or both of the materials will flex under the interference. That adds up to the driving force never getting too great. \\ A note about heating aluminum; as temps rise, so does it's affinity for galling. | ||
| * Bushing groove placement: | * Bushing groove placement: | ||
| - | * Compare the placement of the grooves in the bushings in the 68 and 78 cam covers below. It's the same. \\ Every factory cover is like this. So is the pin placement. | + | * Compare the placement of the grooves in the bushings in the 68 and 78 cam covers below. It's the same. \\ Every factory cover is like this. So is the pin placement. |
| + | * You have to look at the oiling. ((ryder rick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77586-cam-bushings-oil-slot?t=556788&highlight=cam+bushings+slot)) | ||
| + | * You don't want a slotted bushing on the pinion shaft, because that is what feeds oil to the crank. \\ The slot would allow oil to run from the cover into the gearcase, bypassing the pinion shaft hole and starve the crank. | ||
| + | * The intake with the big bushing gets an oil feed hole drilled in it. No need for the slot. | ||
| + | * The slots go at 9 or 3 O'clock on the other 4 (respectively). | ||
| * Grind the flanges from the bushings as required. | * Grind the flanges from the bushings as required. | ||
| * With a die grinder, relieve the #1 & #3 flanges for gear tooth clearance. Grind until you match up with the cutouts in the cover. | * With a die grinder, relieve the #1 & #3 flanges for gear tooth clearance. Grind until you match up with the cutouts in the cover. | ||
| - | * Using general hand tools: ((doodah man of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3)) | + | * Using general hand tools: ((doodah man of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3)) |
| * You can put the bushings in the freezer for a few hours to shrink them some. \\ Then gently tap them in with an extension inserted the wrong way through a socket (smaller than the bushing flange). \\ It may not be the preferred method, but for someone with next to no tools, it does the trick. | * You can put the bushings in the freezer for a few hours to shrink them some. \\ Then gently tap them in with an extension inserted the wrong way through a socket (smaller than the bushing flange). \\ It may not be the preferred method, but for someone with next to no tools, it does the trick. | ||
| * Using a hammer and driver: | * Using a hammer and driver: | ||
| Line 49: | Line 53: | ||
| Click on a pic to enlarge. \\ | Click on a pic to enlarge. \\ | ||
| - | | 1968 Cam Cover Bushings ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904)) | 1978 Cam Cover Bushings ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904)) | | + | |
| + | | Bushings 1,3 and 4 ((photo by billeuze of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77586-cam-bushings-oil-slot?t=556788&highlight=cam+bushings+slot)) | Pinion bushing ((photo by billeuze of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77586-cam-bushings-oil-slot?t=556788&highlight=cam+bushings+slot)) | | ||
| + | |{{:techtalk:ih:engmech:cam_cover_bushing-1-3-4_by_billeuze.jpeg?direct&300|}}|{{:techtalk:ih:engmech:cam_cover_bushing-pinion_by_billeuze.jpeg?direct&300|}}| | ||
| + | |||
| + | | Rear intake bushing ((photo by billeuze of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77586-cam-bushings-oil-slot?t=556788&highlight=cam+bushings+slot)) | Idler gear bushing ((photo by billeuze of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/77586-cam-bushings-oil-slot?t=556788&highlight=cam+bushings+slot)) | | ||
| + | |{{:techtalk:ih:engmech:cam_cover_bushing-rear_intake_by_billeuze.jpeg?direct&300|}}|{{:techtalk:ih:engmech:cam_cover_bushing-idler_by_billeuze.jpeg?direct&300|}}| | ||
| + | |||
| + | | 1968 Cam Cover Bushings ((photo 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-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated?t=1717904)) | 1978 Cam Cover Bushings ((photo 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-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated?t=1717904)) | | ||
| |{{:techtalk:ih:engmech:68_cam_cover_by_dr_dick.jpg?direct&350|}}|{{:techtalk:ih:engmech:78_cam_cover_by_dr_dick.jpg?direct&450|}}| | |{{:techtalk:ih:engmech:68_cam_cover_by_dr_dick.jpg?direct&350|}}|{{:techtalk:ih:engmech:78_cam_cover_by_dr_dick.jpg?direct&450|}}| | ||
| ====== Pining Bushings with Solid Pins ====== | ====== Pining Bushings with Solid Pins ====== | ||
| - | The factory uses pins because they cost less to make and install. Their install procedure is tuned to the tight tolerances pinning requires. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1347648&page=8)) \\ | + | The factory uses pins because they cost less to make and install. Their install procedure is tuned to the tight tolerances pinning requires. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129191-look-at-my-bushings/page8?t=1347648&page=8)) \\ |
| - | * The pins are insurance. On a well done bush job, they don't do anything. What they are there for is to keep a bush that has worked loose in the cover from rotating. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904)) | + | * The pins are insurance. On a well done bush job, they don't do anything. What they are there for is to keep a bush that has worked loose in the cover from rotating. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated?t=1717904)) |
| * What the factory did: Holes are .1215" / .1220". Pins are .1222" / 1224". The holes are drilled and then reamed. | * What the factory did: Holes are .1215" / .1220". Pins are .1222" / 1224". The holes are drilled and then reamed. | ||
| * Now the FSM says to drill and install the pins. It never works out as well as the factory job. \\ Try to drill a hole in any material and hold .0005". It's impossible to do at home. \\ It's extremely difficult in a full machine shop and even then, it's hit and miss. That's in one contiguous piece of material. \\ Try drilling a hole that's half in bronze and half in aluminum. Now it truly is impossible. | * Now the FSM says to drill and install the pins. It never works out as well as the factory job. \\ Try to drill a hole in any material and hold .0005". It's impossible to do at home. \\ It's extremely difficult in a full machine shop and even then, it's hit and miss. That's in one contiguous piece of material. \\ Try drilling a hole that's half in bronze and half in aluminum. Now it truly is impossible. | ||
| Line 68: | Line 79: | ||
| If you have access to a machine shop, it would be a simple guide to make. \\ | If you have access to a machine shop, it would be a simple guide to make. \\ | ||
| - | | Bushing Pining Jig ((photo by 62 Ironhead of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=4)) | | + | | Bushing Pining Jig ((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/page4?t=1717904&page=4)) | |
| |{{:techtalk:ref:tools:cam_bushing_pin_drill_guide_by_62_ironhead.jpg?direct&300|}}| | |{{:techtalk:ref:tools:cam_bushing_pin_drill_guide_by_62_ironhead.jpg?direct&300|}}| | ||
| Line 86: | Line 97: | ||
| * In order to avoid broken taps: | * In order to avoid broken taps: | ||
| * Drills and taps from the supply house aren't very expensive. \\ If you double up and practice the whole operation on some scrap, you will have a much more secure feeling on what your doing when you get to your cam cover. | * Drills and taps from the supply house aren't very expensive. \\ If you double up and practice the whole operation on some scrap, you will have a much more secure feeling on what your doing when you get to your cam cover. | ||
| - | * Locate the holes to be tapped in the beefiest cover material area. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1347648&page=8)) | + | * Locate the holes to be tapped in the beefiest cover material area. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/129191-look-at-my-bushings/page8?t=1347648&page=8)) |
| * Your cutting tools need to be very sharp or you will have problems. Even slightly dull drills and taps will tend to bite into the aluminum and skid off the bronze. | * Your cutting tools need to be very sharp or you will have problems. Even slightly dull drills and taps will tend to bite into the aluminum and skid off the bronze. | ||
| * Drill and tap dry (oil makes this phenomenon of 'walking' worse) making your holes crooked and crappy. | * Drill and tap dry (oil makes this phenomenon of 'walking' worse) making your holes crooked and crappy. | ||
| Line 92: | Line 103: | ||
| * Once the hole is drilled and tapped install set screws. If need be, you shorten the leading end of screw. \\ Then GENTLY peen the top of hole so they can't unscrew into the rotating cams. You may need to remove the screws in the future. | * Once the hole is drilled and tapped install set screws. If need be, you shorten the leading end of screw. \\ Then GENTLY peen the top of hole so they can't unscrew into the rotating cams. You may need to remove the screws in the future. | ||
| - | | Types of taps ((photo by Dr Dick, annotated by Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904)) | Set screws installed to pin the bushings. ((photos by doodah man of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3)) || | + | | Types of taps ((photo by Dr Dick, annotated by Hippysmack 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?t=1717904)) | Set screws installed to pin the bushings. ((photos by doodah man of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3)) || |
| |{{:techtalk:ref:tools:types_of_taps_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:engmech:set_screws_to_pin_the_cam_bushings_1_by_doodah_man.jpeg?direct&300|}}|{{:techtalk:ih:engmech:set_screws_to_pin_the_cam_bushings_2_by_doodah_man.jpg?direct&300|}}| | |{{:techtalk:ref:tools:types_of_taps_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ih:engmech:set_screws_to_pin_the_cam_bushings_1_by_doodah_man.jpeg?direct&300|}}|{{:techtalk:ih:engmech:set_screws_to_pin_the_cam_bushings_2_by_doodah_man.jpg?direct&300|}}| | ||
| ====== Reaming Bushings ====== | ====== Reaming Bushings ====== | ||
| - | Reaming a hole is no more than a hole sizing operation. If the drilled hole is not on location and square the reamed hole will not be either. ((~Grind~ of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=2)) \\ | + | Reaming a hole is no more than a hole sizing operation. If the drilled hole is not on location and square the reamed hole will not be either. ((~Grind~ 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)) \\ |
| Boring the hole with a milling machine is the best option if possible. \\ | Boring the hole with a milling machine is the best option if possible. \\ | ||
| - | For those guys who want the best job they can get, don't ream at all. Make your own bushes and in-position bore them in a mill just like the factory does. ((Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=2)) \\ | + | For those guys who want the best job they can get, don't ream at all. Make your own bushes and in-position bore them in a mill just like the factory does. ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2)) \\ |
| * The reamer wants to 'walk off' instead of cutting. It will only cut if the walk is resisted. What resists the walk? | * The reamer wants to 'walk off' instead of cutting. It will only cut if the walk is resisted. What resists the walk? | ||
| Line 105: | Line 116: | ||
| * Once the reamer is cutting, it's the O.D. of the reamer being held by the newly reamed I.D. that it has just created. | * Once the reamer is cutting, it's the O.D. of the reamer being held by the newly reamed I.D. that it has just created. | ||
| * So, what happens if the I.D. of the pre-reamed bushing is out of position (like if your bushes are not concentric)? \\ Your position goes to Hell, that's what. | * So, what happens if the I.D. of the pre-reamed bushing is out of position (like if your bushes are not concentric)? \\ Your position goes to Hell, that's what. | ||
| - | * Reamer sizes: \\ See also [[techtalk:ref:tools147?s[]=reamer#calculating_pre-ream_drill_hole_sizes|Calculating Pre-Ream Drill Hole Sizes]] (includes a pre-ream drill hole size chart) in the Sportsterpedia. \\ The reamer size and the holes they are supposed to produce is nominal. ((DR DICK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=2)) | + | * Reamer sizes: \\ See also [[techtalk:ref:tools147?s[]=reamer#calculating_pre-ream_drill_hole_sizes|Calculating Pre-Ream Drill Hole Sizes]] (includes a pre-ream drill hole size chart) in the Sportsterpedia. \\ The reamer size and the holes they are supposed to produce is nominal. ((DR DICK of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page2?t=1717904&page=2)) |
| * 9/16" (.5625) for idler. | * 9/16" (.5625) for idler. | ||
| * 5/8" (.6250) for pinion. | * 5/8" (.6250) for pinion. | ||
| Line 115: | Line 126: | ||
| * None of the #2 bushing options are gonna be cheap ($123 for a carbide tipped stub reamer) \\ That is cheap for solving this problem, if it does in fact solve it. \\ But there probably aren't many who agree that $123 is a cheap way out. | * None of the #2 bushing options are gonna be cheap ($123 for a carbide tipped stub reamer) \\ That is cheap for solving this problem, if it does in fact solve it. \\ But there probably aren't many who agree that $123 is a cheap way out. | ||
| - | |A reamer cuts along its chamfer angle, \\ not on its outside diameter. ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904))|Bridge and Hand Reamers have a starting taper that \\ is too long for blind hole work. Each has a different \\ starting taper angle. ((photo by Dr Dick of the XLFORUM http://xlforum.net/forums/showthread.php?t=1717904&page=3))| | + | |A reamer cuts along its chamfer angle, \\ not on its outside diameter. ((photo 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-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated?t=1717904))|Bridge and Hand Reamers have a starting taper that \\ is too long for blind hole work. Each has a different \\ starting taper angle. ((photo 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-1957-1985/160109-changing-out-cam-bushings-help-on-a-couple-of-questions-appreciated/page3?t=1717904&page=3))| |
| |{{:techtalk:ref:tools:reamers_4_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ref:tools:reamers_2_by_dr_dick.jpg?direct&300|}}| | |{{:techtalk:ref:tools:reamers_4_by_dr_dick.jpg?direct&300|}}|{{:techtalk:ref:tools:reamers_2_by_dr_dick.jpg?direct&300|}}| | ||
