Fun in the garage on a friday night......

[BA80]

Getting ready for the Iron Horse Rally in NC.

My scoot started skipping in second gear so I had to fix it before heading to the rally. I took another set of gears I had and dremmeled the dogs on second gear before I even took mine apart. Sorry, no pics of that.

I didn't want to takeeverything off the top of the bike and turn it upside down like I did on my 79 and I didn't want to try and do it sitting on the center stand because that would be even more frustrating than it already is.

So, I hung the damn thing from the rafters.




Not as easy as flipping the bike but not as difficult as screwing with it on the floor.




I finally got the new fixed gears in after a great deal of cussing and beer. The secondary shaft went in easy but that detent on the shift drum will make you want to scrap the whole bike.



Anyway, the hard part is done. I just have to reassemble the pan, clutch, and side covers now.

[bikerphil]

Yep, me and Cobia did one that way except we used an engine hoist. It was kind of awkward with the bike swaying back and forth at times, not too bad though.

[jwhughes3]

"great deal of cussing and beer"

Hows that different from other Fridays?

Glad youre getting it fixed before XSSE...

Making any other mods along the way?

John

[BA80]

Yep, me and Cobia did one that way except we used an engine hoist. It was kind of awkward with the bike swaying back and forth at times, not too bad though.

Heh heh...yeah, laying on that creeper trying to get that #&*$@ shift drum detent into place while a 600lb bike is swaying over your face is a little disconcerting

"great deal of cussing and beer"

Hows that different from other Fridays?

Glad youre getting it fixed before XSSE...

Making any other mods along the way?

John

Nothing really, I just had some justification.

No new mods. I like it just the way it is.

I did put a 110 front tire on it this time when I replaced the tires. It seems to feel a little better in the corners but it made the bike stand a bit taller. Both tires touch the ground when it's on the center stand now.

[trbig]

You did swap the washer on 2nd gear.. right?

[trbig]

Never mind.. I zoomed in on the pic and saw that you have.

[BA80]

It would be foolish not to swap that while in there.

And yes I loctited the bolt behind the clutch and and the oil pump bolts.

I couldn't find a torque spec for that bot so I just torqued it to 60 ft lbs. That should be good.

[JeffH]

Getting ready for the Iron Horse Rally in NC.

Actually looks to me like some sort of Wheelie Practice!! Workin' in a new stunt using the creeper .......

Glad it went back together ok and if it shifts great like it should, then well worth the preventive effort before something got all jacked up in the tranny.
SE Rally date is coming up soon and we are all looking forward to it.

Jeff

[bikerphil]

The torque for the washer based bolt on the countershaft is 51 ft/lb according to the FSM. You should be fine with 60, don't want that sucker coming out.

[BA80]

Thanks Phil, The torque is 51 on the clutch center nut also and I figured it would be close to that so I just added a few ft lbs and went with that. I put Loctite on it too. Both Tod and Ivan have had issues with them backing out and being eaten by the gear on the back of the clutch.

Well, I have it all back together and discovered 2 things. 1-there was NO check valve in the oil filter bolt so my oil has been bypassing the filter since last fall when I removed the oil cooler in order to install the fairing. I replaced that. 2-my cheap harbor freight come-along is junk. When I was letting the bike back down that POS let go and the bike dropped the last foot in freefall. I had the centerstand down and all was fine but it took a minute for my heart to start up again.

Gotta go put the fairing back on and test ride to make sure I haven't made it worse than it was.

[BA80]

Well, my luck is holding in negative numbers as usual. Got it all back together and took it for a shakedown.

Good news....2nd gear works great.

Bad news....I didn't look at 1st gear on this shaft close enough. Now it's skipping in 1st.

So, I get to tear it apart all over again.

Took the first gear off of the shaft I took out. It was working good but I figured I would clean them up while I had the opportunity. Took som pics.

First I cleaned up and slightly back cut the lands in the receiving slots.



There was a little rounding of the edges of the dogs.


So, I cleaned them up and slightly back cut/dove tailed them a little.



I'm gonna get me a compressor and some air tools when I tear into it again. Maybe tomorrow. That will save a TON of time. Also need to devise a tool for that $#*&^@ detent. I have an idea unless someone has already come up with something.

Live and learn.

[trbig]

What detent are you talking about? If it's that springloaded one that rides along the little star looking thing that actually holds the shift cam in the proper place when you shift.... you've already dropped the oil pan, so just remove the bolt holding that in. It's just a pin and spring under that bolt there. Put it back in when you're done and bend the metal tab back up to lock the bolt in place.

[BA80]

Tod, the ONLY thing that holds that little#$%ard in IS the star thing on the end of the shift drum and you have to get it in under the star before the drum will go in. All the while keeping the forks in place.

I'm not talking about the pin that holds the drum in on the left side. It's that little spring loaded bastard on the right, on the clutch side..

[DGXSER]

Are you pulling the shift drum out to perform the gear fix? I am lost as well as what detent your talking about. I have never pulled the shift drum or even messed with either end of it to perform the second/1st gear repair.

[BA80]

If your not removing the drum I can't see how your removing the shift forks and if your not removing the forks I don't see how your getting the gears out.

The red arrow points to the detent star on the right end (clutch side) of the shift drum.



This little bugger here......



Here's a pic of it in it's receptical with the spring below it...

.

You don't take that out to get the secondary shaft out? I need to know how you do that.