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  1. #41
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    Top shifter removed with no issues as expected, the sprocket bolt tool worked just as good as the Jims one at 1/3 the price




    Only from a view of the exposed portion, that is a tired main shaft.... what could oil tight seal on that thing????????






    Inner side of sprocket





    Oil drained, started clutch nut loosened, mounted back on bike to do so....





    What a mess, countershaft endplay is .017!!! This will mean new bushings, not just shims i bet. .012 is max, .005/6 is ideal.




    Kicker gear bolt should be 30/40 lb/ft this is 0 with the lock washer holding it together, ill disassemble to see if this ate the bushing next.



    And thats it for today......

  2. #42
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    I knew this was rusted on and required penetrating oil for several days,



    Followed by several round if heating and cooling with propane, and light percussion in between. It came off.



    Rusting and pitting on the mating surfaces, the source of the trouble.



    All pieces removed from this assembly





    Mainshaft bearing / countershaft retainer bracket.



    Rust evident on race



    Shift forks removed



    Ready for countershaft gear extraction
    Last edited by jcrubin; 03-24-2019 at 9:58 PM.

  3. #43
    SamHain
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    Those mainshafts leak by design. Somebody came up with putting an Oring groove in the spacer, works pretty good when everything’s in order, tricky to install.

    That along with cleaning up the main shaft and cutting a high gear bush at .001 clearance.

    http://www.caimag.com/wordpress/2010...real-solution/

  4. #44
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    Quote Originally Posted by SamHain View Post
    Those mainshafts leak by design. Somebody came up with putting an Oring groove in the spacer, works pretty good when everything’s in order, tricky to install.

    That along with cleaning up the main shaft and cutting a high gear bush at .001 clearance.

    http://www.caimag.com/wordpress/2010...real-solution/
    Standby, ill be posting photos including the mainshaft shortly, looks like gravel was used as transmission fluid

  5. #45
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    Countershaft removal



    Countershaft, nothing major noticed



    Counter Gear cluster removal



    Ready for pack and storage

  6. #46
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    Tap out shaft




    Inspect




    Mainshaft removal




    Remaining Gear




    Pulled




    Empty Case




    Alt View 1



    Alt View 2

  7. #47
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    This is actually difficult to photograph


    mainshaft 1




    mainshaft 2




    mainshaft 3




    mainshaft 4
    Last edited by jcrubin; 03-26-2019 at 9:30 PM.

  8. #48
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    Kicker cover parts disassembly




    Complete clean-out and degreasing




    Shaft cleaned but end slightly bent (will be replaced with kit 630-350)




    Other items cleaned for install, no damage




    Reassembled




    Gear damage 1 (will be replaced with kit 630-350)




    Gear damage 2 (will be replaced with kit 630-350)




    Temporary reassemble





  9. #49
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    Before you put that tranny back together, look into replacing that main drive gear bearing with an early setup. The narrow caged bearing does not hold up as well as the loose rollers. Your machinist can bore the case to fit the early bearing race. Just a thought

  10. #50
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    Ive looked at that, and while there are benefits, I go from simply pressing a bearing to becoming beholden to a machinist to the task as well as subsequent repairs to this setup which becomes quite complex going forward.

  11. #51
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    Top plug removed




    C Clip




    Disassembly




    Emptied




    Lever




    Springs removed




    Cleaned and decontaminated




    Cleaned springs installed

  12. #52
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    Mainshaft Bearing nut removal




    Pressed out





    Bearing dents





    Mainshaft





    Adhoc Bearing Puller





    Case Cleared





    Crusty ass bearing




    Washing Machine

  13. #53
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    Holy smokes. As a fresh owner of an 82 FXS... I'm glued to this thread (and officially overwhelmed/terrified of what I've got myself into). Ha.

    Nice work tho man. I appreciate all the photos and descriptions and attention to detail. I'll re-read this a few hundred times for sure.

  14. #54
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    Quote Originally Posted by bpeak View Post
    Holy smokes. As a fresh owner of an 82 FXS... I'm glued to this thread (and officially overwhelmed/terrified of what I've got myself into). Ha.

    Nice work tho man. I appreciate all the photos and descriptions and attention to detail. I'll re-read this a few hundred times for sure.
    The original AMF manual is fantastic. It's a good idea to study it and become proficient. Its much cheaper and more rewarding to do the work yourself.

  15. #55
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    Cleaned tested neutral switch




    Carrier Clean







    Carrier Test fit




    Cleaned cam




    Cleaned Pawls




    Spacers

  16. #56
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    Pawl carrier assembly
















    Cam stop








    Installed

  17. #57
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    Old shifter seal vs. New




    Adhoc install tool




    New Seal

  18. #58

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    great photos! cant wait to see more of this build!

  19. #59
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    The videos from where these stills came are starting to slowly come out under another thread here

    http://www.chopcult.com/forum/showth...447#post818447

  20. #60

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    Quote Originally Posted by jcrubin View Post
    The videos from where these stills came are starting to slowly come out under another thread here

    http://www.chopcult.com/forum/showth...447#post818447
    great detailed video man! thanks!

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