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Ourdee
Posted on Friday, October 09, 2020 - 11:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

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Tootal
Posted on Saturday, October 10, 2020 - 04:16 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

With the bearing in place I set the 6th gear/output shaft in the bearing:





I used the long socket and a backup plate to pull the output shaft through the bearing:









So that all went well:





I also put the seal on. I tried to install the swingarm but the trans housing is evidently mushroomed and I'm going to have to file the high spots off of it. Then the neighbor called and can't start his lawnmower. Pulled the cover off and found a rodent had built a nice home and ate his sparkplug wire in half! Another job down for parts!
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Pwnzor
Posted on Saturday, October 10, 2020 - 05:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Never misunderestimate a squirrel.

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Hughlysses
Posted on Saturday, October 10, 2020 - 10:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Greg- We’re headed back to Little Switzerland for a few days later this month. Maybe you can finish up and ride it down!
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Tootal
Posted on Sunday, October 11, 2020 - 09:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The plan is to vote on Nov.3rd. I'm showing up in person. Not that my vote means anything in the Peoples Republic of Illinois, it's just the principle! Then I plan to ride it to Florida, if it's not snowing by then! I have two big jobs at the brewery coming up, so I'm losing a week of working on the bike. As much as I'd like to meet up it's just not in the cards. I'll feel fortunate if I can get it back together by election day! I'm also trying to get my buddy's racecar ready for next weekend. And here I thought I retired!!
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Tootal
Posted on Monday, October 12, 2020 - 12:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

After filing a while on the trans housing it was obvious that there's no way to maintain it's perpendicularity with the bore. I needed to know the high spots. I went to the shop and made a disk that would tightly fit on the original pivot shaft for the swingarm. I glued some emory paper to it and mounted it on the shaft.





I put blue Dykem on the surfaces and just turned it by hand to show the high spots:









I then used a drill motor to slowly turn the disk to take out the high spots:





Giving me this:








At this point I tried installing the swingarm again but it still wouldn't go. All I can figure is the new shims are thicker that what I took out or it was wrong from the factory and they forced it on which would have worn out the bearings prematurely. Whatever the case, I double checked my installation of the bearings and spacers and all is correct so I'm just going to keep sanding this down until it fits. I wore out the emory paper and have glued on a courser piece. In the last fitting it went on half way and quit. Since the bearings are self aligning as soon as they straighten out they lock up. I'll continue to take a little off each side until it fits snug but freely. Nothing is ever easy...
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Ratbuell
Posted on Monday, October 12, 2020 - 12:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Something is tickling the back of my brain, thinking something about a spreader tool for the frame that's required for swingarm installation?
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Tootal
Posted on Monday, October 12, 2020 - 12:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I read the service manual twice and it just says to install it and insert the pivot shaft. No mention of specialty tools. Besides, it slid right out during disassembly.
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Greg_e
Posted on Tuesday, October 13, 2020 - 11:39 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My 05 didn't require any special tools to fit the swingarm, but mine also went right back on without issue. I don't think I even had to swear at it.
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Shoggin
Posted on Tuesday, October 13, 2020 - 02:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That facing tool is brilliant! Well done sir
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Tootal
Posted on Tuesday, October 13, 2020 - 05:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I just wish I had some emery cloth a little coarser than 150. It clogs up too easy on this aluminum. I got it to about an 1/8" of going on. Had to glue some more on. In the mean time I finally installed some handlebar risers on the Uly. They've been sitting here for a while. I took it for a ride and noticed my idle was a little high when I got back. I turned the grip closed to make sure is wasn't sticking and the cable broke!! It broke at the throttlebody. There must have only been one wire left on the cable as you could tell it's been frayed for a while. So now it's down for cables. I also found out why it would miss every once in a while. My magnecore front plug wire had almost rubbed in half against the engine. Might as well order some new tires while I'm at it!
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Ourdee
Posted on Tuesday, October 13, 2020 - 08:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

yalp
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Buellish
Posted on Tuesday, October 13, 2020 - 09:11 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I had a badly frayed throttle cable on the Uly after I bought it.Gave me an excuse to get in there and clean the throttle body.
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Hughlysses
Posted on Tuesday, October 13, 2020 - 10:44 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Greg- You might try using WD40 as a sanding lubricant to prolong the life of your emery cloth. Oddly enough, unlike water, it won’t dissolve the glue on conventional sandpaper so it would probably work fine with emery cloth. I used that trick to level a tractor cylinder head with a piece of quartz countertop as a flat surface a few months back.
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Tootal
Posted on Wednesday, October 14, 2020 - 10:55 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Mike, you read my mind, it was a mess and I rerouted the breather lines already. So I have cables, plug wires and tires on order for the Uly. I'll throw in some new spark plugs while I'm here too.

Hugh, I'll give it a try. I've got the cloth just glued on with Elmers which works great. It's actually hard to peel it off and then I have to use a wire wheel to clean the glue itself off.
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Tootal
Posted on Wednesday, October 14, 2020 - 03:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well patience won in the end! I sanded both sides again this morning and tried to fit it. It didn't seem like it wanted to but the right bearing is a little tight so I took a small pry bar and pulled it in a little on both sides and it slid right into place with no endplay and it moves freely.

We have alignment!





Pivot shaft in place:





So the main output of the trans and the swingarm are in place:





I'll start installing the transmission gearset next.
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Ourdee
Posted on Wednesday, October 14, 2020 - 05:58 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yay!
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Tootal
Posted on Saturday, October 17, 2020 - 03:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well, I lied a little. I decided to finish up the swingarm first. I installed new rubber bushings and got everything clean and loctited. When done there was no side movement and it was very stiction free. I was really happy with the way it ended up even if it did require a lot more work than it should have. So the axle is back in and it's off the jack. I started prepping for the trans gears installation and was putting the gasket on when I discovered a missing dowel pin. I've looked all over and it's not there. So down again until I get one. If the dealer doesn't have one I'll pull the other one out and measure it and buy it locally. It doesn't take much to throw a wrench into best laid plans!
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Ourdee
Posted on Saturday, October 17, 2020 - 05:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I've made dowels out of drill bits with a dremel.
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Tootal
Posted on Sunday, October 18, 2020 - 12:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That works. I have some small diameter brass in the shop, if nothing else I'll make one out of that. It's just an alignment dowel, it has no purpose once the screws are tight.
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Tootal
Posted on Sunday, October 18, 2020 - 08:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well I went to breakfast with my brother and told him of the missing dowel pin. When we got home he looked in his basement and found some 5/16" dowel pins. The smallest was an inch and five sixteenths. I made it 5/8" with a die grinder. Problem solved. So the tranny is back in. I cleaned up the clutch actuator and cover. When I removed the clutch cable I found the o-ring looking like this:



So it wasn't a huge leak but it explains some of the oil in the area. So then I started cleaning the shift forks and I saw this:





It looks like something melted onto the steel or the chrome peeled back and the friction caused it to blue. Very strange. Before I try to clean it I'm going to show the guy who installed it originally and see if he's seen anything like that before.
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Tootal
Posted on Wednesday, October 21, 2020 - 02:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

So we've deciphered that when the shaft the shift forks ride on bent it cocked the fork putting side pressure on it. Then me riding 160 miles back home with it stuck there caused extreme heat which trashed the fork. The other forks show minor wear but not bad but I'm replacing all of them. I just got off the phone with Baker and I'm $157.00 poorer. I did check the groove on the gear and there is some discoloration but the steel shows no sign of wear. The fork was the sacrificial lamb. Good design! So we await parts yet again however I did get my plug wires for the Uly and also a shipping notice for the throttle cables. So the Uly should be back soon. My new tires are showing up sometime today but I'll wait till the Harley is off the lift before I change them.
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Griffmeister
Posted on Wednesday, October 21, 2020 - 05:50 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Maybe Magnaflux the stressed gear just in case?
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Tootal
Posted on Sunday, October 25, 2020 - 02:45 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'm not concerned with any cracks. It was just the groove the fork rides in and I checked it dimensionally compared to the others and it's fine. I received the new forks and installed them along with the clutch actuator housing and the oil filler casting:





You can see the new forks in place:





The shift drum was next and other than the top cap and one oil seal on the input shaft the trans is back together. As soon as I make an installation tool for the seal I will seat it and then pour fresh oil over the shift drum and install the cap:





I centered the shifter pawl as per Baker and went through the gears. It feels real good! Fortunately I have all my parts to finish the job, it's just time now which is going to be hard to come by this week. I'm afraid there's a worm drive gearbox rebuild in my immediate future. We're pulling it out tomorrow to diagnose, I'm really hoping it's the motor making the noises!!
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Buellish
Posted on Sunday, October 25, 2020 - 04:48 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I bought a cosmetically tatty '97 S1 with a Baker 6 speed trans,fixed the cosmetic issues and swapped the 6 speed into my Ice White Pearl S2.I didn't go anywhere on that S2 where the 6th gear was useful except rarly on I75 to run errands down in Marietta.Mostly I road it in the mountains and never went into 6th.I ended up selling the Baker.It was a really nice transmission but I don't travel on a bike like you do.
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Tootal
Posted on Sunday, October 25, 2020 - 09:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I totally get that. I really like the XB9 gearing in those mountains too! Although, if the Uly had a 6 speed and I had a granny low for off road use, I'd love that! This Road Glide turns 2900 rpm at 75 MPH. With the torque cam I run, it will cruise all day like that, nice and relaxed. You're right though, totally different type of riding!
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Ratbuell
Posted on Sunday, October 25, 2020 - 09:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If you'd run the Baker 6 in the S1, you'd have appreciated it. The S2 has longer legs due to the belt pullies. A baker 6 on an S2, with S1 pullies and belt...that would be sweeeet.
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Tootal
Posted on Wednesday, October 28, 2020 - 12:06 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well nasty weather moved in yesterday so on Monday I needed to get the Uly back together because all the parts I had off were on my trailer which was in the garage getting the wheels balanced. Don't you love having multiple projects at the same time! So I got the new throttle cables installed and they worked fine with the bar risers. Then the new spark plug wires. The old magnecore wires were about 6 inches long and I had raised my coil up 3/4" so it wasn't so tight in there putting pressure on the idle cable and the lower throttle cable. Well, the new wires are like 4 inches long! I had to put the coil back down to get them to work. I don't like it like that but I didn't have any choice at the moment. Anyway, it's all back together for now. Tires and a new belt await it's future.
Today I'm going to try and borrow some specialty tools from my buddy. I was going to make them but I might not ever need it again so we'll see.
The good thing is the trailer is done, the Uly is done for now and I can get my car back in the garage!
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Two_seasons
Posted on Wednesday, October 28, 2020 - 02:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I like this thread.

Tootal said "Don't you love having multiple projects at the same time!"

Tell me about it!

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Buellish
Posted on Wednesday, October 28, 2020 - 06:30 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

"Don't you love having multiple projects at the same time!"

You mean like master bathroom,wood shop,bike shop,Uly,Guzzi,DL650 and Pontiac.That kind of multiple projects?
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