| Author | Message | ||
     Ft_bstrd |
So, today.......it begins. Tear down day one.     | ||
| Ft_bstrd |
I was happy to see that the output shaft bearings looked good. I wasn't happy to see that the mainshaft bearing spacer was broken.   So the question is, can I get just the spacer? If not, is this a pressed in bearing? If so, I'm assuming that means pulling the transmission out? | ||
| D_adams |
For that one, I'd pull it apart and replace the bearing if it were me. | ||
| Brother_in_buells |
Well when you are this far ,pulling the trans isn't that difficult anymore! | ||
| Ft_bstrd |
From the manual it doesn't look that bad. Give me a chance to inspect the bearings on the backside of the countershaft as well as the shifter shaft. | ||
| Bonneville |
Good luck with the project, it'd be good if you could post photos of your progress.  | ||
| Ft_bstrd |
Will do! | ||
| Reepicheep |
Pfft. Now that you are that far in, you are only 4 bolts from having that transmission out on your work bench. Even if that bearing wasn't toast, you would still want to pull it to check the forks, drum, and 5th gear drive assembly bearings. Lucky you saw this when you did! The transmission comes apart pretty easily too, I had it apart and back together in a couple of days. Having both the service and the parts manual together is handy to see how it goes back together, and I was pretty insanely careful about laying it out in a safe place in a 3d exploded diagram with a piece of string through everything to keep it in the right order. If you gave me everything loose in a box, I probably *could* puzzle it out, but it would take a lot of time and it would be easy to make a mistake. I would look very closely at the 5th gear drive assembly. It gets poor lube circulation, lots of moisture, and lots of load. | ||
| Jim2 |
This happened to me. I believe the primary chain "too tight" is the main contributor. The service manual specs are too tight. The bearing is pressed on to the shaft. I took my transmission in a box to my local bearing shop and had them press off the bearing. There is a spacer between the bearing and shaft that must go on before the new bearing is pressed back on. It is easy to loose track of the spacer when you hand your parts off to the shop and get it back in pieces. | ||
| Ft_bstrd |
Most of this bike's life, it was owned and maintained by someone else. Considering the aluminum muffler was installed with the hanger hanging from the stock hanger, I don't take that he was very handy with tools. | ||
| Imadog |
I am confused, should not there be more balls in the bearing?? | ||
| Ft_bstrd |
I don't think so. It only has 7 (at least there are seven sockets in the race. | ||
| Ratbuell |
Jeremy is correct - when properly spaced, the bearing balls are nowhere near in contact with each other. Without a race, they have the ability to "fall" into contact with each other as shown. Properly installed, there's nearly a ball-sized space between the balls in order to promote oiling. | ||
| Ft_bstrd |
The groove in the inner bearing surface looks good and unmarred. Same for the outer bearing surface. Oddly, the ridge at the top (outside edge) of the groove has some gouges. The bearings themselves look good. Wondering what wonders await me when I pull the transmission out. | ||
| Reepicheep |
If you have it apart, look for raised lips on the shift drum where the pin rides, and file them flat again. Then check the dogs on each gear pair, it doesn't take much rounding before they get start to "half engage" or pop out. | ||
| Ft_bstrd |
Overall the transmission shifts well. It's never popped out of gear or failed to shift gears. In just the "peep through the hole and inspect while you turn the shaft" inspection, the gears look really good. Virtually no wear. We'll see what it looks like when I pull it out, though. | ||
| Ft_bstrd |
Teardown day two:       Happily transmission gears, shift forks, needle bearings all look good. No chunks of anything in the bottom. | ||
| Ft_bstrd |
Although, I will admit that knot in my stomach wondering whether I'll actually get it all back together. | ||
| Reepicheep |
That 5th gear drive assembly looks pristine... Lucky you! | ||
| Ft_bstrd |
I thought it looked pretty good too. | ||
| Jayvee |
Isn't this where you would "back cut" the shifter dogs, or undercut the transmission, or whatever you call it to make it shift easier? | ||
| Ft_bstrd |
Beats me. It didn't shift badly before. | ||
| Mhlunsford |
You an replace the bearing. Another option is to get a trans off of ebay out of a sportster. There are some minor differences - be aware. I ended up piecing together two trans to get one to work. | ||
| Phelan |
What differences did you find in the transmissions? AFAIK any differences would be pertinent to the year rather than model it came from. | ||
| Reepicheep |
You back cut the dogs, which are the 5 or so big square posts you can see on the picture above where each big gear slides over to engage the other big gear. It doesn't take much rounding of those sharp edges for the transmission to not completely engage when you shift. The result will be that when you hit the throttle it will either completely pop out of gear, or more likely, feel like it jumped a tooth then *slam* into place on your first hard acceleration after a shift. Ft's transmission, based on the picture above, appears to be about half way to where my M2 started having problems. Here is a nice comparison shot from a post by PikeBen08 showing worn dogs.  | ||
| Natexlh1000 |
yeah. My X1 got a hopping second gear just like that and the wear/damage was HARD to see. The pic above looks much worse than my X1 tranny. Thos dogs have a keystone looking profile so that they lock in together. Mine was a right angle instead. | ||
| Ft_bstrd |
Close up of the dogs.  | ||
| Ft_bstrd |
Tear down day three.    | ||
| Rjn |
Been there, done that! Took me 2 years to get it back together  | ||
| Ft_bstrd |
You hush up. |
