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techtalk:ref:svcproc9a [2024/05/02 00:59] hippysmack [1965 XLCH Transmission Assembly] |
techtalk:ref:svcproc9a [2024/05/02 01:40] hippysmack ↷ Links adapted because of a move operation |
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====== REF: Service Procedures 9A ====== | ====== REF: Service Procedures 9A ====== | ||
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- | ====== 1965 XLCH Transmission Assembly ====== | + | ====== 1975 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)) \\ | 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)) \\ | ||
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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. \\ | 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. \\ | ||
- | {{: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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_andrews_gears_1_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_andrews_gears_3_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_andrews_gears_5_by_scottericsonon.jpg?direct&400|}} \\ |
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Empty trapdoor. \\ | Empty trapdoor. \\ | ||
I should note that while it was empty, I DID punch out the countershaft oiler plug so I can set endplay later. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_trapdoor_1_by_scottericsonon.jpg?direct&400|}} \\ |
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Clutch gear with new bearing loaded into trap. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_trapdoor_2_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_mainshaft_loaded_1_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_mainshaft_loaded_2_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 41: | Line 41: | ||
Then tear it back down and then start reassembly WITH the shifter forks. \\ | 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. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_countershaft_loaded_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic1_by_scottericsonon.jpg?direct&400|}} \\ |
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(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). \\ | (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. \\ | 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|}} \\ | + | {{:techtalk:ref:svcproc:1965_xlch_tranny_pic2_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic3_by_scottericsonon.jpg?direct&400|}} \\ |
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Here is the transmission completely assembled to measure clearances on the gears. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic4_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic5_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 58: | Line 58: | ||
Put it in neutral to measure your clearances. \\ | 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. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic6_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic7_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 64: | Line 64: | ||
(R) Then measure between the dogs on C/S 3rd the face of C/S 2nd like this. \\ | (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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic8_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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. \\ | (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. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic10_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic11_by_scottericsonon.jpg?direct&400|}} \\ |
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Checking C/S clearance. I have .006" \\ | 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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic12_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic14_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic16_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic17_by_scottericsonon.jpg?direct&400|}} \\ |
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(L) Checking the M/S endplay. I have .006" \\ | (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. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic18_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic19_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 93: | Line 93: | ||
MAKE SURE you put the flat washer in between the circlip and your bearing rollers!! | 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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic20_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic22_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic23_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 106: | Line 106: | ||
Then when they're all tight, pull them one at a time and put a dab of Loctite on them. \\ | 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. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic24_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic25_by_scottericsonon.jpg?direct&400|}} \\ |
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Slide the clutch shaft parts on with the collar first then the spring and the gear. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic26_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic27_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 118: | Line 118: | ||
(I put a new plastic shoe on mine obviously) \\ | (I put a new plastic shoe on mine obviously) \\ | ||
(R) Gather up your primary chain, crankshaft gear and clutch basket. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic28_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic29_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 129: | Line 129: | ||
Crank gear nut is 1-1/4" while the clutch basket is 1-1/2". \\ | Crank gear nut is 1-1/4" while the clutch basket is 1-1/2". \\ | ||
(R) gather up your clutch parts. \\ | (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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic30_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic31_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 142: | Line 142: | ||
There's a certain spacing they have to be at. \\ | 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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic32_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic33_by_scottericsonon.jpg?direct&400|}} \\ |
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Line 149: | Line 149: | ||
(R) Ok, now let's move over to the right side of the bike for a bit. \\ | (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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic34_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_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. \\ | 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|}} \\ | + | {{techtalk:ref:svcproc:1975_xlch_tranny_pic36_by_scottericsonon.jpg?direct&400|}} \\ |
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+ | |||
+ | Well here we are with the last installment of the trans already. Getting the shifter on (I need to pull the peg out of my old one). \\ | ||
+ | Get your drive chain around the sprocket loose. Yeah you can wait and install the cover first but you make more work for yourself?? \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic37_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic38_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | Get the cover on swearing at yourself for getting fingerprints all over it. Get the bolts in and try to clean up the cover a little bit. \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic39_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic40_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | Kickstarter spring... just muscle it on....I grabbed the outer end with a pair of vice grips and the really helped a lot. \\ | ||
+ | You want that spring under a little tension. Get the kickstarter on with the pinch bolt. \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic41_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic42_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | (L) Get the chain around your rear sprocket and hook your master link with the CLOSED ROUNDED end of the master IN THE DIRECTION OF TRAVEL. \\ | ||
+ | That means if you hooked it on the bottom side of the sprocket the CLOSED END should be towards the REAR of the motorcycle!! Got it??. \\ | ||
+ | (R) Adjust your chain etc. I shouldn't have to tell you how to do this...look in your manual. \\ | ||
+ | Grab your coffee and go back over to the left side of the motorcycle. \\ | ||
+ | Get your 2 threaded 1/4 rods that you used in your clutch compressor and put them in the cases like this. \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic43_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic44_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | Slip your new gasket over the rods. \\ | ||
+ | Oh, before I forget, get your clutch cable threaded back into your primary cover and hook it up. \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic45_by_scottericsonon.jpg?direct&400|}} {{techtalk:ref:svcproc:1975_xlch_tranny_pic46_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | Slip your primary cover over your 2 threaded rods making sure you leave a tiny gap. In other words don't seat it all the way. \\ | ||
+ | Get all your screws started using the gap to see that they go thru the gasket correctly.. \\ | ||
+ | Once they are all started, go ahead and GENTLY tap on the primary cover with the heel of your hand to seat it. \\ | ||
+ | Once it's seated, snug up a couple screws and then replace the threaded rod with the proper screws. \\ | ||
+ | Tighten these all up using a criss-cross kinda pattern so as to not warp the primary cover. \\ | ||
+ | {{techtalk:ref:svcproc:1975_xlch_tranny_pic47_by_scottericsonon.jpg?direct&400|}} \\ | ||
+ | \\ | ||
+ | |||
+ | Adjust your clutch per the FSM, fill her up with oil, put your footpegs and pipes back on and go bang some gears! \\ | ||
+ | You're done!! | ||
+ | |||
+ | Actually I'd take it pretty easy on the trans for your first couple rides and make sure I went back and retightened a handfull of bolts after a few hot/cold cycles of the motor. I hope you found this thread both entertaining and informative. I know I sure had a blast doing it as well as learning a lot. Maybe it will inspire some of you to write a little something about your own project. Now get out there and enjoy your ironhead whether you're going out for a ride...turning some wrenches.....planning some future mods or just daydreaming about past rides!! | ||
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[[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] | [[:techtalk:menu|{{:techtalk:gototechnicalmenu.jpg|}}]] |