transmission mainshaft
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1st Gear
Joined: Jun 2007
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transmission mainshaft
hello, i'm new the fourm. i'm try to set the endplay on my 72 xlch, i have a sevice manual, the way they decribe setting it is kinda fuzzy. any input would be a great help.....by the way if your wondering i'd take to a shop but someone dosen't learn much about there machine doing things that way and besides they look at me funny when i tell them the year of the bike.
Tourer
Joined: Nov 2006
Posts: 407
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From: georgia
RE: transmission mainshaft
Folks here wouldnt look at you funny.Time to find an old shop where they still have appreciation for a bulletproof motorcycle.And do it yourself-ers usually respect and dont abuse..welcome to a great forum. respectfully Ladyhawke
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: transmission mainshaft
Do you have your transmission pulled and on a bench? You will have to do this to check and shim if required.
Press the clutch gear (that is the clutch sprocket shaft) all the way towards the door mount.
At the opposite end of the mainshaft (this is where the rear sprocket attaches) mount a dial indicator. With the indicator in place and set to zero, push in on the clutch gear towards the dial indicator end. How many thousandths does it move? If it is within specs, then all is fine. If it is not, then you need to install shim washers. There are 5 different thickness shims available for the mainshaft and 8 available for the counter shaft. You need to check both shafts.
Now, if your transmission has not been apart and is running and shifting fine, I would recommend that you leave well enough alone. The trans will be fine if this is the case.
If, on the otherhand you have had it apart then you will certainly want to check the end play of both main and countershafts.........pg
Press the clutch gear (that is the clutch sprocket shaft) all the way towards the door mount.
At the opposite end of the mainshaft (this is where the rear sprocket attaches) mount a dial indicator. With the indicator in place and set to zero, push in on the clutch gear towards the dial indicator end. How many thousandths does it move? If it is within specs, then all is fine. If it is not, then you need to install shim washers. There are 5 different thickness shims available for the mainshaft and 8 available for the counter shaft. You need to check both shafts.
Now, if your transmission has not been apart and is running and shifting fine, I would recommend that you leave well enough alone. The trans will be fine if this is the case.
If, on the otherhand you have had it apart then you will certainly want to check the end play of both main and countershafts.........pg
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1st Gear
Joined: Jun 2007
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RE: transmission mainshaft
The tranny is still in the bike. the way the sevice manual reads it has to be in the bike to check endplay. the books tell two diffrent ways to check for end play. one with the clutch assembled and and with clutch disassembled. with the clutch assembled and disengaged, it shows that there is little to no end play and thats without any shims. if i put the clutch springs behind the clutch hub aginst the trapdoor and then put the nut on loading the clutch gear shaft(basicly forcing the shoulder of the gearshaft aginst the inner race of the bearing in the trapdoor) then i show endplay..........the only thing i know for sure is i'm doing something wrong.
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: transmission mainshaft
I do not know what repair manual you are using, but the procedure is done with the trans on a bench. You can check the mainshaft end play with the trans installed (without the clutch installed) but what are you going to do if it needs shims? Pull the trans of course.
And how do you propose to check the countershaft end play without removing the transmission? This shaft is basically trapped inside the transmission bearings with no way to move the shaft back and forth without it being removed from the case.
If you install the clutch, the spring pressure will force everything to the left side and all play will be taken up. It will be inpossible to move the assembly back towards the right side where the dial indicator goes to measure end play. You have me really baffled about what your book says.
If you are using a Clymer manual, then that explains it. If you are using a factory manual, then something is being misread on your end.
If you do not own a factory manual then PM me and I can scan and email you the information in pdf form................pg
EDIT NOTE: xlch72.....Here is what I am referring too. Difficult to put in type, but you need to have the trans door off to do the check. Just follow this to do the check. Is this just like your manual?
And how do you propose to check the countershaft end play without removing the transmission? This shaft is basically trapped inside the transmission bearings with no way to move the shaft back and forth without it being removed from the case.
If you install the clutch, the spring pressure will force everything to the left side and all play will be taken up. It will be inpossible to move the assembly back towards the right side where the dial indicator goes to measure end play. You have me really baffled about what your book says.
If you are using a Clymer manual, then that explains it. If you are using a factory manual, then something is being misread on your end.
If you do not own a factory manual then PM me and I can scan and email you the information in pdf form................pg
EDIT NOTE: xlch72.....Here is what I am referring too. Difficult to put in type, but you need to have the trans door off to do the check. Just follow this to do the check. Is this just like your manual?
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1st Gear
Joined: Jun 2007
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RE: transmission mainshaft
no, mine says to install the tranny and check it in the bike, it also says that the countershaft endplay can be done throuh the tranny oil plug hole with a spoke
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Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: transmission mainshaft
Received your PM. You have the correct book. Do as the book says. The trans has to be out to access the spacer shim installation. Yes, the door goes into place to do the check, but the door has to come off to add or remove the shims.
I still do not understand where the instruction tells you to check it with the clutch installed. That makes no sense to me at all.
Again, if you are having shifting problems pull the door. If not, I suggest you leave things alone. Being curious about a transmission can cause you some problems that you may not have (yet)......pg
I still do not understand where the instruction tells you to check it with the clutch installed. That makes no sense to me at all.
Again, if you are having shifting problems pull the door. If not, I suggest you leave things alone. Being curious about a transmission can cause you some problems that you may not have (yet)......pg
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Joined: Sep 2007
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From:
RE: transmission mainshaft
Listen to Piniongears advice. If your tranny is shifting ok right now, don't pull it out. I had a Harley mechanic (big twin)friend pull mine out because sometimes it would jump into nuetral while sitting at a redlight. After four weeks and much frustration he gave up on fixing the problem and gave me the bike back with it jumping out of second gear every shift. I later had another mechanic check it out and he said it was shimmed up all wrong and that I had some bad gears (gear clutches?) that needed replacing. I checked the parts he recommended and they totaled over $600 so I just bought a new Tranny from V-Twin for $900 and had him install it. The tranny is good now, but my flywheel has since come apart and the old 79IH is at Competion Motorcycles in Pearland Texas for a complete rebuild. On the bright side... I'll have a new engine and tranny when it's all said and done, but alot less money in the bank. I had a couple of friends ask me why I didn't scrap the 79 and buy another used bike... my reply was because I love myoddball old 79 Ironhead.
go figure
Aubrey
go figure
Aubrey
Road Warrior
Joined: Dec 2007
Posts: 1,666
Likes: 3
From: Styxville
RE: transmission mainshaft
Hi,
I know it has been a while since this was posted and the tranny is probably rebuilt by now, but I have just been going through the same process myself and there may be others out there wondering too, or in the future.
The factory manual for my 77 xlch says that before measuring the mainshaft endplay, use the clutch compressing tool to push the clutch in towards the transmisson casing before measuring endplay. It says if the clutch has been removed, use the tool to push the clutch gear shaft in towards the tranny trapdoor.
It says to then measure the end play using a dial gauge on the other end of the mainshaft, where the gearbox sprocket mounts. Or if you are old school enough, you can "feel" how much endplay there is. Otherwise, I just used a feeler gauge between the sprocket and the seal holder.
It seems to me, the clutch gear needs pushing inwards before measuring end play because the main clutchbearing is a loose fit in the trapdoor and can move sideways between the two snap rings by about .010".
So when you are setting the endplay in the mainshaft, it seems it is really only the minimum endplay, because in operation, the bearing at the other end will allow extra movement. Like most things on Ironheads, the old beast dont seem too fussy about fine tolerances.
Another thing I have found while I have been playing with the gearbox, is that out local bearing supplier says he can get me a super heavy duty bearing to replace the big clutch shaft bearing in the trap door. It has extra ***** in it and is designed for heavy transmission work in trucks etc. It should last longer than the ordinary type. If it works out, I will post details.
I know it has been a while since this was posted and the tranny is probably rebuilt by now, but I have just been going through the same process myself and there may be others out there wondering too, or in the future.
The factory manual for my 77 xlch says that before measuring the mainshaft endplay, use the clutch compressing tool to push the clutch in towards the transmisson casing before measuring endplay. It says if the clutch has been removed, use the tool to push the clutch gear shaft in towards the tranny trapdoor.
It says to then measure the end play using a dial gauge on the other end of the mainshaft, where the gearbox sprocket mounts. Or if you are old school enough, you can "feel" how much endplay there is. Otherwise, I just used a feeler gauge between the sprocket and the seal holder.
It seems to me, the clutch gear needs pushing inwards before measuring end play because the main clutchbearing is a loose fit in the trapdoor and can move sideways between the two snap rings by about .010".
So when you are setting the endplay in the mainshaft, it seems it is really only the minimum endplay, because in operation, the bearing at the other end will allow extra movement. Like most things on Ironheads, the old beast dont seem too fussy about fine tolerances.
Another thing I have found while I have been playing with the gearbox, is that out local bearing supplier says he can get me a super heavy duty bearing to replace the big clutch shaft bearing in the trap door. It has extra ***** in it and is designed for heavy transmission work in trucks etc. It should last longer than the ordinary type. If it works out, I will post details.
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