Villageidiot destroys a perfectly nice sportster.

Discussion in 'Some Assembly Required' started by villageidiot, Oct 26, 2018.

  1. sealsam

    sealsam Sam...I am. Supporter

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    If that happens, could try it out to Orig Pancake!:dukegirl
  2. villageidiot

    villageidiot Long timer Supporter

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    ill keep ya posted on that. this the last weekend before we bail for 2 weeks, so theres a buncha shit to get in order, but ill see what i can make happen.
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  3. villageidiot

    villageidiot Long timer Supporter

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    D9929E51-7586-4F6A-8B75-4725C9117F24.jpeg

    All geared up
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  4. villageidiot

    villageidiot Long timer Supporter

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    Got to work early this morning, took the trans with me so I could get it apart and back together, garage is 110* when I get home from work and it’s no fun to work in.

    Here’s the old first gear on countershaft, note the beveled edges of the shift dogs. Since the dogs don’t engage 100% when shifted, it’s more like 50%, that bevel edge really hinders shift engagement. Smoother I’m sure, but potential for sooner problems.

    5A07ECF6-220A-4576-AA0D-4BA2BBC11038.jpeg

    Old vs new, the new gear has MUCH LESS bevel on the gear all the way around. Updated part number usually means updated parts, they knew there was issues, nice to see it updated.

    A7D6D5B1-4100-43B9-ACE4-6D49FEE5498D.jpeg

    3rd gear countershaft, same thing, new is nice n square, old much more bevel on the edge.
    46CAB337-6490-4C63-A5EA-90BC892BFCAA.jpeg 36369D7D-4A6C-4DEF-876C-0EF06467FBF8.jpeg
  5. villageidiot

    villageidiot Long timer Supporter

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    AF6538BF-2F19-4B6F-93F1-6D54967DCC82.jpeg

    Trans all spread out.

    Got it all apart, and back together, new split cage bearings, new first and third countershaft gears, new snap rings, new shift detent plate and clip.

    No pics of the process, oily hands and all that.

    Should go in the bike this weekend. Not sure what day, I have to work at the shop and wrap up some shop shit so the cars can leave before my trip.
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  6. villageidiot

    villageidiot Long timer Supporter

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    E0298DCD-68DF-41C8-BA64-39447529C96F.jpeg

    all back together and ready to take home
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  7. Kai Ju

    Kai Ju Long timer Supporter

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    Why is 3 in the middle ?
  8. villageidiot

    villageidiot Long timer Supporter

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    I dunno.

    I didn’t build it
  9. Kai Ju

    Kai Ju Long timer Supporter

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    I thought those were your markings...never mind.
    Can't believe the bevel on the stock slots, that just invites failure.
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  10. villageidiot

    villageidiot Long timer Supporter

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    No, those markings were there when I dis assembled it. 3 is in the middle, it’s over 3rd gear countershaft and engages 1st and (I think) 5th.
  11. sealsam

    sealsam Sam...I am. Supporter

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    Glad to see some serious progress on the HD.

    Especially cool seeing the pics of what the internals look like on the trans. For us 'non-mechs' this is pretty eye opening!!

    Good luck today, hope to see it road worthy soon.

    Think pancakes brother!!
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  12. Kai Ju

    Kai Ju Long timer Supporter

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    I've seen lots of Japanese and BMW transmissions, this is the first HD I've seen.
    Interesting that it is a 'cassette' type gear box and as such looks like one of the easily accessible transmissions I've seen.
    Also very interesting shift fork arrangement in that the pins that ride in the shift drum channels are not part of the fork.
    To wit, here is a Japanese transmission. You can see the pins forged with the fork itself.
    The fork are also quite slender and prone to bending with a severely missed shift.

    upload_2019-8-31_9-46-40.png

    Sorry about the thread jack.
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  13. villageidiot

    villageidiot Long timer Supporter

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    This trans was out on the bench in 2 hours including a run to my work 10 miles away for a socket, and a run to harbor freight for another size socket.

    Shift forks are super stout and bronze/brass.

    It’s a cassette, loads in with 5 bolts. Quite nice really. Harley did away with that in the sportster in 2004. Gotta split the cases now to pull the trans down.
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  14. TUCKERS

    TUCKERS the famous james

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    Great progress...………………..
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  15. villageidiot

    villageidiot Long timer Supporter

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    Hoped to have it in the bike today, but I had to do a set of differential mounts on a 72 280se 4.5, the lower one came out in 3 pieces, was a bitch. I was at work at 5:40, just got home at 12:45.

    Garage is 100* plus. It’s also my 11 year wedding anniversary so I don’t think I’ll be getting any work done on it today.

    I’ll be back at it tomorrow morning. Should be able to get it all wrapped up
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  16. TUCKERS

    TUCKERS the famous james

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    Concentrate on your family first is admirable.
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  17. AK650

    AK650 Long timer Supporter

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    Happy Anniversary VI and missus VI!
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  18. sealsam

    sealsam Sam...I am. Supporter

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    Happy 11th my friend, my condolences to the lovely Mrs. VI.
  19. villageidiot

    villageidiot Long timer Supporter

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    Interesting, I thought I had posted a pic of me and my bride on our wedding day, but for some reason, it’s POOF, gone.

    No alert, no reason, it wasn’t obscene, or anything like that, I don’t understand.
  20. Rich B

    Rich B Long timer Supporter

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    Happy anniversary VI!
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