| Author | Message | ||
     Dj_engine |
Long time no see, hope everyone's well and whole. First I want to thank Buellistic, who PM'd me very detailed howto's on the innards of the tuber drivetrain. I've followed his advice and gotten the extra plates to delete the spring plate in the clutch pack. The backstory: A while ago, I found out I got worn dogs in 2nd gear. This was OK temporarily. I figured I could deal with the occasional lunge, so I kept procrastinating. But then I lost 5th gear. A couple of months ago, I lost 4th. Then it kept jumping out of 3rd. When I put it in the garage, it wouldn't even come out of first. Last week I said screw it, off comes the primary. I didn't find anything wrong with that, so I pulled the clutch and sprocket. Nothing obviously wrong with the detent plate or shift pawl, so out came the trans. I can't believe how frighteningly easy it is to remove the transmission from one of these bikes. Of course, unless you're a fairly big dude (which I'm not), you're going to have to get clever with breaker bars and extension handles. With the trans out, I found that the fork closest to the trapdoor plate is jammed somehow. The shift drum will only turn about 1/4 turn, and like an idiot, I broke off one of the drum pins testing this fact. Also, as suspected, the dogs on 2nd are rounded off big time. It's a wonder second gear engaged at all. So that leads me to the subject of this post: I bought a 1993 Sportster transmission off eBay to slot in as a temporary solution while I work up the time, patience and funds to rebuild the one I just took out. Will it drop right in? Will it work with the existing output gear? Or do I get to press out the drive gear and replace it with the one that came with my eBay trans? cheers, -John | ||
| Dj_engine |
Update: Got home, found that yes indeed, the gears are totally different between the 93 and the 00 transmissions. This is fine. I now get to install the 5th gear output that came with the fleabay trans. I imagine it will soon shift like that 92 RW1200 I saw on a showroom floor a while back but was never able to buy. | ||
| Dj_engine |
Update #2: It's all done. The 93 transmission drops right in with one notable exception: the gear teeth on the 5th gear output shaft rub on the speed sensor. Not for long though. I think possibly because of this, I no longer have a speedometer. The miles still keep counting up though, so maybe if I picked up a pre-95 speed sensor, it would probably work. Not critical though, I know my speeds by rpm. Speed sensor problems aside, it shifts smoother than it ever has. Something to be said for proper shift pawl adjustment as well. And the best thing? No more worn-dog lunge! Lafayette, I did your grenade plate fix. Definitely different clutch action, but I like it. Thanks! Still, this is a temporary solution. This whole bike is on borrowed time anyway. Since the first wreck, it's had a salvage title, and when I get to the point where I've put more money in than the insurance company paid out, I'm going to see about upgrading to an 1125R or at least a newer XB. | ||
| Dj_engine |
Update #3: Every time I post something on this board, I go away, do some research, then feel like an idiot as soon as I learn something contrary to what I posted. I think I have the process backwards - research first, then spew text into forum. For instance, the speed sensor on the '93 bikes were mechanical, so it seems (notice the qualifier there) that a pre-94 speed sensor isn't going to solve anything. What will solve this issue is an aluminum plate between the speed sensor and the case. A piece of .063 in the vast pile of scrap from my airplane project should do the trick. This should lift the sensor out of the way of the output shaft teeth. Of course, I should have thought of this before I used 5th gear to grind off the end of the sensor. Live and learn. Assuming that fix works (there I go again), to get actual speed and miles, I should be able to multiply the speed/miles reading by the ratio of the number of teeth on the oldschool 5th gear to the number of teeth on the newschool 5th gear. Or divide. Math is fuzzy, coffee hasn't kicked in yet. It'll be like doing tax and tip on a restaurant tab in my head, which I can handle, most of the time. I'll find out if I can do it in traffic. This is important, because I use miles to calculate how much fuel I have left. When the low fuel light comes on, I've maybe got two or three miles left before the tank runs dry, making fueling a right-now situation instead of in-a-minute. |
