Assembly and Transmission

Got down to the nitty-gritty and assembled the sandwich.

Snicked the transmission through the gears no problem, so it seemed I got the junk cleaned out and all is well. Put on the oil pan, snicked through the gears. Put on the generator shaft, no problems with gears. Put on the timing plate and all of a sudden the same problem I had when I started this mess has come up - first gear and neutral only. So I rotated the crank and nothing changed. The engine still has to have the clutch, generator, middle gear, output shaft and 4 covers installed.

What happened? Do I need to re-split the cases? Did I miss something? Please tell me that this is OK and I can keep going, or what needs to happen now. The preference is to keep going, but if I have to pull the engine and begin again I would rather fix it now and do the remaining work once.

Any help appreciated.

 

will the shift drum turn?

 

Correct me if I'm wrong, but without the clutch basket in when you turn the crank, it's not turning any of the transmittion shafts??
Not knowing exactly what order or how far you are, you should be able to reach in where the clutch sits and turn the shaft and let the gears mesh.

 

Ah-HA! Bingo!

Mike- you sir have saved my blood pressure and about 50 hours of jigging and cursing. I owe you a big favour. If I am ever in Eastern Penn, I'll let you know. Funny how this little detail escaped me.

Thanks - this is the best site for a reason. Kudos and a thousand thanks.

 

Glad to help.
Being half way through a case swap on my spare engine I know how many hours you have into it at this point and I would hate to wish extra work on anyone.

 

...more power than a locomotive, with a trusty steed named "Plum Crazy" able to leap tall buildings in a single bound--can chirp 2nd gear--with a cloud of dust, and hearty shout of "Man, that's an awesome bike!"....(Look! Up the road! It's a 'bird! Wait...it's a plane! No....it's....hmmm, what the @$%# is it!?!?!?--it sure ain't a Harley!.......OH!It's the Lone SuperMike! To the rescue!

 

As it turns out.....
After getting the engine assembled, clutch in, all 4 side covers on with the generator left, I look down and what do I see but a bearing half-ring from the input shaft.

Dammit!! What an idiot! How did I miss that...used egg cartons to keep parts separate and easily seen, but this piece seemed to elude my eyes.

After a night of kicking myself in the ass (and a beer or three), next evening I re-split the cases, placed the half-ring, cleaned the seams of the cases, re-checked to be sure nothing else was missed, re-sealed the seam, put the sandwich back together and torqued the case shut. Cleaning the seams and bolt thread locker took the most time. Next evening looked after the clutch and shifter assemblies, oil pan and 4 side covers, so in 2 days the engine is back where it was after three months of bits-at-a-time work.

Amazing what familiarity and a little controlled anger can get done.

Alternator, then running the attached wiring and the heart will be ready for framing. Next item will be cleaning all the clips and connectors of corrosion. Is there a QEW (quick & easy way) to do so?

 

You did pay close attention to applying Yamabond or a similar sealer to the critical points in the motor as you reassembled, right? Around the case stud holes but not within 2-3mm of the bearing shells?

 

Yeah fitz, re-sealing the seams is Pete-speak for that step. And a pain it is, though a necessary one. But I'd rather do that than caulk a bathtub. Or have to re-split the cases. Or stick my hand in a vise. Or....

 

Glad to see you're nearing completion

 

Me too ghost as riding season is a month early and I am without a ride and two weeks behind my pals. It should be ready for the April 1st deadline set back in October. The Big Day is the May 1st Bike Blessing - gotta be there for that - I'll take all the luck I can get.

Best way to clean the connectors anyone? Is it just as simple as contact cleaner and a brush or does the 28-years of corrosion and road grime need something special? I am just wondering if the wrong material or method will cause damage to these old parts?