Continuing on from yesterday.....

And finally for the day, put the new stator in. Had to push the wire assembly through the hole, and then pull the wire from the outside until the rubber seal came through and "set". The stator went right into position on it's little shaft, and I used new screws like the manual said. Used the small torque wrench, and tightened her down to 70 inch pounds.....


Ran out of time, but it's good to be on the way back up hill. Hoping to finish it up Thursday. Will post pics of the rest of the journey.

Ride on, ride well.

Doug

"I took the one less traveled by,
And that has made all the difference."

 

Great post and excellant and clear pictures.Your post is sure to be a big help to others.

 

doch4m,

Just a suggestion. You might want to replace the arm that goes on that shift shaft while you have your inner primary off as preventitive maint. and loc-tite the splines. Those arms like to strip the splines a few hundred miles after re-installing the innerprimary.[:@]

V2

 

Good point Vbagger. I know of several guys that have broken that arm. I fI were doing this job, I'd think about a new shift arm if my bike had lots of miles. Maybe this bike is still quite low mileage, what then.
Doch4m, I'm thinkin' you should have mentioned that if you were doing this job again, it would be a good idea to clean the crap of before disasembly. JMO
thanks foe this , it is real informative, should be posted in the DIY forums without everyone elses comments.

 

[quote]ORIGINAL: Wally

Good point Vbagger. I know of several guys that have broken that arm. I fI were doing this job, I'd think about a new shift arm if my bike had lots of miles. Maybe this bike is still quite low mileage, what then.[quote]


What then??? Its an $11.00 part. Do you realise the inner primary has to be removed to replace that arm??

 

Clearly worth while changing on any bike that has had it removed.

 

Wally,

Yes, it would have been good to clean off the junk prior to. But I have no running water at the barn, so that made it a little harder for me. Also, you guys "scared" me into buying the new inside shifter arm. $21 from the dealer.

Ride on, ride well.

Doug

"I took the one less traveled by,
And that has made all the difference."

 

Well, well, where to start. Maybe with a Proverb. "Pride goes before destruction, a haughty spirit before a fall".

First of all, thanks for all of the kind words, encouragement, and other thoughts. Up until Friday, I was feeling really good about this whole adventure. Maybe got a little too full of my self and my "abilities". Well, maybe Friday doesn't count as destruction, but certainly was a fall. Spent several hours, in three different sessions, in the barn, and nothing seemed to go right. Got right nasty in my spirit and in my disposition as the day went on.

I don't even have many pictures to share. Since the new shifter shaft seal and the new stator were in, I thought I could easily get the primary back together. Cleaned up the rotor with some gasoline and an old toothbrush. Was some nasty gunk in there, probably from the fried stator. Then used the steering wheel puller to slowly and safely slide it back on. That went OK.....


Attached, let it in slowly and lined it up on the shaft splines. See the new (blue) rubber O ring gasket.....


The Inner primary case has two seals, one for the starter jackshaft and one for the trans/clutch shaft. Decided to replace those as well. What a pain. It took alot of work and trial and error to get the old ones out, and the new ones in. Unfortunately, no pictures. Finally got it done and cleaned up the case. OK, should go better now. I'll put the inner primary case on. Put RTV Silicone in the screw holes, followed the manual and the parts diagrams to a T. Torqued it all down and bent the lock tabs down. Wow, that shifter rod assembly looks real tight. Why, it won't move?

Played with it for a while to see what I did wrong. The rubber spacer was between the inner case and the shaft that the shifter foot pegs attach too ON THE MOTOR SIDE, just like the diagram showed. That jammed the whole assembly against the motor. It seems to me that the rubber spacer was OUTSIDE the chaincase, right next to the shifter pegs. Yes, now I remember, it was on the outside. Stupid book. Unbent all the locking tabs, getting ready to take the inner chaincase off. Growl. Wait. That spacer is just rubber, and has to be cheap. Used a small screwdriver and a hammer and punched it through and took it out. I'll get a new one. That relieved the pressure, and the shifter assembly was now free. I'm so smart! Glad I don't have to take off the inner chaincase again after all!

Now let's put the starter jackshaft pieces in. Lined everything up. Didn't go all the way in. Loosened the starter, still no dice. Re-read the manual. There is a shaft coupler, behind the inner chaincase that has to be turned the correct way, even though it fits either way. Must have that backwards. Unbent all the tabs AGAIN, removed the inner chaincase. Cleaned up all the still wet silicone. Turned around the coupler, and started over. Finally got it back on, set all the tabs, and the starter pieces fit just right. Arg. The inner chaincase, finally on correctly (I think).....


Took a little break. Back to work. Let's get the primary back together. Put the chain and sprockets back on their shafts, and got ready for the big (75-250 lb.) torque wrench. Lined everything up, reading the manual carefully. Here is a picture.....


Two drops of red locktig

 

OK, today (Saturday) HAD to be better, right?

Put my HB-125 tensioner back in. So far, so good.....


Adjusted the clutch and cleaned the gasket edge real good. Put the outer primary (chrome cover) over a new gasket, and torqued her down.....


Put the small (chain inspection) cover with a new gasket on and torqued it down. I had also drained the tranny a couple of days ago, so I double checked the drain plugs, and put 22 oz. in the trans. and 32 oz. in the primary. After Friday, I just knew that it was all going to leak right out on the carpet, because I left something open underneath. But alas, it must be OK, cause it was all dry underneath! Put the old gasket on the clutch cover, and torqued that down as well. After a run or two, I am going to drain the primary, put new fluid in, and put the new gasket on. I'm afraid there may still be some gunk from the old stator and some dust from the 10 days it all sat out in the barn that the fluid will pick up. Kind of ****, but that's the plan. Here is the finshed photo.....


And my broken tool from Friday.....


More to come soon. Was a happy tinkerer again.

Ride on, ride well.

Doug

"I took the one less traveled by,
And that has made all the difference."

 

More progress today (Monday). Still sane and happy!

Figured I could get most of it done this am while my sweetie was out for breakfast with a girlfriend and then went to the grocery store.

First, I needed to connect the new stator wires to the voltage regulator plug. New wires from the new stator on top, old stator wires, still in the plug below.....


Pulled out the old stator wires with the plug that needs to be re-used.....


Pulled out the old wires, following the manual.....


The new wires put into the plug.....


Time for a test. Put the battery back in, along with my new charger/tender plug. Triple checked everything to make sure I was ready for startup. Put the voltage tester into the plug from the stator.....


It should read about 20 volts AC for each 1000 rpm, if the stator is working. Started the bike, and had over 20, up to over 60 at 3000 rpm. Shut her down. Yipee skipee!

Hooked in the plug to the VR, and tightened it all down, according to the manual.....


Started her up again, and checked the DC voltage across the terminals. 14.3 to 14.4. The dash volt meter looked good also. Great.

Put the floorboards back on.....


Here is an "aftermath" photo. Just need that rubber washer/spacer for the shifter pegs, and a good day to clearcoat my "new" red front fender. She looks like she is itching to get out in that sunshine and hit the road.....


When the fender and the wheel go back on, I'm ready to ride! Tomorrow is supposed to be nice, so I hope to get the fender and wheel done and back on.

Here is my new battery tender that will always be plugged in when the bike is parked.....


Looking forward to a test ride later this week to double check the electrical system. Will post a final (I hope!) report then.

Ride on, ride well.

Doug

"I took the one less traveled by,
And that has made all the difference."