The FXS Shovelhead rebuild project

[thecarfarmer]

You may be dealing with hi-wear on the main-shaft and fourth gear inner bushing....

Try rocking the sprocket with two screw drivers or pry bars....



This will give ya an idea of how much the bushing/bearing is worn ...

Holy crap!

that's sprocket was bouncing around and wobbling like a fat drunk on a skateboard.

Damn near got seasick watching that...

[jcrubin]

You may be dealing with hi-wear on the main-shaft and fourth gear inner bushing....

Try rocking the sprocket with two screw drivers or pry bars....



This will give ya an idea of how much the bushing/bearing is worn ...

most helpful, I will test this tomorrow

[jcrubin]

Click this link for a video I made, there is deflection, as shown here, is this what you are referring to?

https://i.imgur.com/q8GzeXn.mp4

[Davestune]

Thoughts on this? I can't see going for 200$ for JIMS for something I use every five or so years....

https://www.ebay.com/itm/Harley-Davi...bBvo:rk:2:pf:0

i have that tool you will be fine, mine is non jims allso

[Davestune]

Also it's only got 16,000 miles and the original paint.....

yes but u have to love ugly, embrace ugly, and well look ugly haha
she is a beauty

[Davestune]

make sure to check the oil pump bushing in the case, and dont forget those rods need to be straight like some one said early

[jcrubin]

Click this link for a video I made, there is deflection, as shown here, is this what you are referring to?


https://i.imgur.com/q8GzeXn.mp4

Click this link for a video I made, there is deflection, as shown here, is this what you are referring to?

https://i.imgur.com/q8GzeXn.mp4

[Dragstews]

Looks a bit tried to me....

Wouldn't be a bad idea to fresh up the tranny with new bearings and bushings, most likely a new mainshaft will also be needed.
Might see some other parts that are on their last legs while yo're in the belly of the beast... Shift Clutches takes a whooping and the forks are hi-ware items...

[jcrubin]

Looks a bit tried to me....

Wouldn't be a bad idea to fresh up the tranny with new bearings and bushings, most likely a new mainshaft will also be needed.
Might see some other parts that are on their last legs while yo're in the belly of the beast... Shift Clutches takes a whooping and the forks are hi-ware items...

The tranny I can do in house....

Im gonna new a few extra specialized tools to do the complete job though. I hope to get the engine off to the machinist this weekend then I can put the tranny on the bench

[jcrubin]

With the bottom end at the machinist, I had time to pull the tranny

[jcrubin]

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......

[jcrubin]

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

[Guest]

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/2010/02/04/finally-a-cure-for-the-always-leaking-4-speed-tranny-a-real-solution/

[jcrubin]

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

[jcrubin]

Countershaft removal



Countershaft, nothing major noticed



Counter Gear cluster removal



Ready for pack and storage