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Williamscottrobertson
Posted on Wednesday, February 20, 2019 - 09:25 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Doing my first work on the transmissions on these bikes. The S1W I’m working on had been sitting several years because the PO said it “Lost a couple gears”. Well, the primary tensioner was broken in two, one half was still on the nut, I never found the other half. I assume it went into the transmission and was shredded because there was a lot of shredded metal. I pulled the transmission and a couple of the dogs are shot and a couple gears are broken.

Anyway, I purchased a whole new transmission in great shape with zippers trap door. It came with the main shaft gear and my plan was to pull it and put in the one that was mated to this gear set and replace the seal while I was at it. However, it doesn’t just slide out. And the FSM calls for some special pulled tool and to replace these needle bearings and all this. Maybe I can put a screw into the seal and try to pull it out and the breakdown shows a lock ring. Can I remove the lock ring and pull out the main shaft without removing the main shaft bearing? Is there a better way to remove the seal? I hate running screws into seals for fear of getting into the bearing behind it.
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Williamscottrobertson
Posted on Wednesday, February 20, 2019 - 02:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I pulled the seal easy with a screwdriver once I removed the inner bushing. The lock ring was on the entire bearing bore, so it looks like there’s no easy way to remove the main. I decided to replace the seal and leave in the main as there didn’t look to be any damage to it and it rolled smoothly. I tapped in a new end seal and installed the other transmission.
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Buellrobot
Posted on Wednesday, February 20, 2019 - 04:01 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If I remember correctly, you're supposed to replace the large bearing that the primary drive rotates in (near the front pulley), because the act of pressing the primary drive puts pressure on the inner race and warps the bearing.

I could be thinking of something totally different, but when I had my X1 transmission redone, the folks that did the work included a fresh (very large) bearing to replace the previous one – and that it was supposed to be replaced any time the transmission/main shaft was removed.
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K12pilot
Posted on Tuesday, February 26, 2019 - 09:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have pulled & swapped many transmissions never having to change a bearing.... ???

I do pack both needle bearings that accept the shaft swith Moly grease.

Aslo, I pop the seal out of the drive pulley & pack that bearing, as it doesn't get much fluid up there.
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Buellrobot
Posted on Wednesday, February 27, 2019 - 02:19 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

This is roughly the explanation that Mark (owner of R&D Motorsports in florida) shared when he back-cut my transmission gears: http://xlforum.net/forums/showpost.php?s=698e4d035 1e5db62cc75a24d5952a4f0&p=2536372&postcount=10

I can't find instructions for replacement in the manual, but it intuitively makes sense that the pressure on the inner race (when pressing the shaft out of the bearing) could warp the bearing.

Also, just to be sure I'm on the same page, here's a picture of the one I'm thinking of (the ball bearing): https://i.ytimg.com/vi/F8FUbFcAd84/maxresdefault.j pg Not entirely sure I'm using the right term : )

(Message edited by buellrobot on February 27, 2019)
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Williamscottrobertson
Posted on Wednesday, February 27, 2019 - 05:37 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

How do you get the main shaft out though? It looked like it was pressed into the main bearing inner race. I just lubed up those needle bearings in the main gear and slid in the new transmission.
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Buellrobot
Posted on Wednesday, February 27, 2019 - 06:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I did this about 4 years ago and am almost certainly mixing up which steps are critical to getting the transmission out.

Pretty sure I sent my 5th gear to R&D and distinctly remember rigging up an intricate DIY tool for removing the mainshaft and/or pressing the new bearing back in.

If you didn't take the mainshaft out, then you shouldn't need to mess with the bearing at all!
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Williamscottrobertson
Posted on Thursday, February 28, 2019 - 07:28 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yeah I was going to take it out to put the mated main shaft in with it if it were simply a lock ring or something holding it in. I figure it’ll be ok, all looked good.
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