Transmission overhaul

[Justin B.]

I have lately became a bit more motivated concerning the Junkyard LS and was a bit bummed when I pulled the tranny to clean/lube the splines.  The input shaft looks brand new but rotating the output shaft was not very smooth.  Disassembly was pretty straightforward (after fabricating a tool to remove the rear drive flange) and putting the $9.95 (on sale) Harbor Freight Heat Gun to use. After the teardown it appears that both bearings on the output shaft are rough so I just finished ordering new bearings (except for the front input shaft roller bearing) and assorted bits from Moto-Bins.  There was quite a bit of brownish "mud" in the bottom of the case and rust on the bearings and shims so apparently it had sat with water in it for a while.

Bearings involved are 1 ea 6403-C3 and 4 ea 6304-C3.  I probably could get away with just replacing the two bearings on the output shaft but figure I'd do the rest of the 6304 bearings as they are pretty cheap.

I have a rear cover that has the clutch arm pivots broken off so I will mill it down to make a "shimming plate" to set the bearing end-float.  Once I get the new bearings I'll measure my clearances and order the necessary shims.

I have pretty much followed the instructions at:

http://jhau.maliwi.de/mot/gearbox.htm#material

[Justin B.]

Here is what I saw after getting the rear cover off.  You can see how rusty the rear output bearing is and the output yoke and speedo drive gear are rusty as well:

[Justin B.]

I had snagged a busted rear cover off e-Bay a few years ago and milled it down to make a bearing shimming plate with:

[Justin B.]

After milling it flat on top I flipped it over and bored holes to access the bearings through:

[nhmaf]

I'm impressed with your lathe, press, and tool-making, Justin !   I wish that I had some of your "toys", and the experience to use them to their fullest.

The transmission doesn't look as bad as I've seen some that "just sat" for a few years - I swear that some bikes spend years literally underwater sometimes before a seller decides it is a restorable classic.

Please keep us posted with your progress - I've got a transmission that is basically good but will need a new input shaft, and possibly new bearing on the front end and I've been debating whether to try to tackle it myself or send it in to a shop.

[Rob Valdez 79 R65]

Nice pictures, Justin!  Thanks!

In that last picture, you can see the corner of an oiling can.  Do they still make these?  I don't need one, myself (I have Grandpas'), but I was wondering if they are still made.  I use mine for filling those hard to reach gear lube orifices.

[montmil]

Nice pictures, Justin!  Thanks!

In that last picture, you can see the corner of an oiling can.  Do they still make these?  I don't need one, myself (I have Grandpas'), but I was wondering if they are still made.  I use mine for filling those hard to reach gear lube orifices.

Saw 'em at Harbor Freight. Old school all the way.   Monte

[Justin B.]

Rob, as Monte says HF has some (small ones), the one in the pic I liberated from Uncle Sam many moons ago... 8-)

[Ed Miller]

I'm impressed with your lathe, press, and tool-making, Justin !   I wish that I had some of your "toys", and the experience to use them to their fullest.

Ditto, with a dash of envy.  You know, for the bit of bitter flavor.  I'll get there somehow, somewhen.  Pretty funny for a guy who's only "B" grades in high school classes were in shop.  

[Justin B.]

I have a pretty modest outlay for machines, got them all on sale at HF.  It is fun/nice to be able to whip up a tool/bushing/fixture/whatever when needed, helps keep a job from stalling when some little gizmo is needed.  I busted my bearing separator (forgot to remove/didn't see the snap-ring on front end of output shaft) and will need to go to HF tomorrow and swap it out and I can then remove the rest of the bearings.  I must make a note to myself to remember to wear my glasses more often when yanking stuff apart!    My bearings should be here this week and I should be able to immediately start putting it back together.  Once I have it together I can then make the measurements and see if I need to order any shims.

[nhmaf]

Justin,

Maybe this standard shim kit from Ed's might cover what you may need, now and in future ?   Price isn't bad, I think.
http://tinyurl.com/dc2orm

Mike

[Justin B.]

I've looked at it but if I only need 1 or 2 shims then it would likely be a bunch of 'em I'll never use.

[Justin B.]

I went by HF yesterday (after Ken from OK left from picking up his Red Smoke S parts) and swapped out my bearing puller kit.  When I got home the bearing I had been fighting came right off.  Always pay attention for this stuff!    I guess my '82 is one of the ones that retained the snap-ring that Snowbum writes about, I feel lucky as I was going to machine my output shaft to accept one.

Hopefully Moto-Bins will be their usual speedy shipping self and I can start putting this back together soon. 8-)

[donbmw]

Justin

Did your output shaft have a grove for the clip. Everything I have read about this said sometime in 84 is when the stopped using the clip. I had my front bearing on my output shaft freeze up and it truned off the shaft and broke the clip.

Don

[Justin B.]

Don, yes, this one has the clip, I had been planning to machine the shaft if it didn't.  I had thought that sometime in '82 it was done away with but according to Snowbum it was '84.  That's how I broke by bearing puller - the snap-ring certainly does it's job well!