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  #21  
Old 15th April 2019, 01:11 PM
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The comb over kid The comb over kid is offline
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Default Re: Pulling the box out of a yank!

Good luck and a lot of patience
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  #22  
Old 15th April 2019, 04:57 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Originally Posted by The comb over kid View Post
Good luck and a lot of patience
Thanks but she's finished thankfully and running perfect.
This is a retrospective thread, just hadn't had time to put up all the pics til now..
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  #23  
Old 15th April 2019, 05:30 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

And so on to the tear down.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

Thankfully the pistons including skirts looked in great condition.
Same with the cylinder bores, although I don't have pics.
With this in mind I decided against replacing the rings since she didn't burn excessive oil (air cooled, so a bit is usual) and no point bedding in new rings unnecessarily.
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  #24  
Old 15th April 2019, 05:39 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

And finally on to the gearbox damage

As suspected the selector for for third was chewed up.
Click the image to open in full size.
Click the image to open in full size.

The dogs on 3rd gear were also chipped.
This is why she'd jump out. Normally the slight overcut would lock the gears in place...
Click the image to open in full size.
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  #25  
Old 16th April 2019, 01:23 PM
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Default Re: Pulling the box out of a yank!

did ya need to remove the motor to pull the gearbox out ?, what dya think done the selector damage ?, is there needle bearings o the shaft/casing on that model or is it bushes or rollers? ive ran into quite a few sportsters with similar woes .
i like the buells , good fun bikes imo . one of the better harleys was a buell design , the fxr .
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  #26  
Old 16th April 2019, 06:38 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Originally Posted by chopper View Post
did ya need to remove the motor to pull the gearbox out ?, what dya think done the selector damage ?, is there needle bearings o the shaft/casing on that model or is it bushes or rollers? ive ran into quite a few sportsters with similar woes .
i like the buells , good fun bikes imo . one of the better harleys was a buell design , the fxr .
I don't know what did the damage, although at a guess maybe previous a owner trying to short shift...
The drum was in good nick, although I replaced it with the new forks.
Maybe the helical cut on the gear giving it a constant thrust against the selector fork wearing it out?
Have you any thoughts?

Yeah she had to come out
I believe some harleys have a trapdoor box? that can bee pulled without splitting the casings?
Not the Buell though, the cases are solid left and right so the heads/barrels need to come off to split the cases and get at the box.

The bearings for the main and countershaft are caged balls on the left side of the engine. When pressing the shafts out of the casing you have to counterhold the outer race to press against so there's a strong chance of damaging them.

On the right hand side there's a blind needle for the countershaft.

I replaced all three of these.

here's a pic of the left case ones.
Click the image to open in full size.

The bearing and belt drive pulley actually stay in place in the casing on that side. The mainshaft is splined on that side and just slots inside it.
It uses a massive needle bearing which needs all sorts of pullers and stuff to remove and reinstall, so since there was no play in it I didn't take it apart.

few pics of putting her back together

Click the image to open in full size.
Click the image to open in full size.
Click the image to open in full size.

And one of the funky Harley split rod crank design that keeps the cylinders in line for those that haven't seen it before.
Click the image to open in full size.

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  #27  
Old 16th April 2019, 06:52 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Actually that last gearbox pic was taking it apart, but you get the idea
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  #28  
Old 16th April 2019, 07:23 PM
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Default Re: Pulling the box out of a yank!

yea the sportsters (which that owes a lot of design to) can get the gearbox out while engines in frame . iirc the earlier buells had a retuned sportster motor . a lot of the sporty gearbox woes were down to worn bearings .
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  #29  
Old 16th April 2019, 07:33 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Ah right cool, this was my first time going near a HD motor so was a nice learning curve.
Would have saved a lot of time and hassle if it could have been pulled while in the frame!
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  #30  
Old 17th April 2019, 07:19 AM
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Default Re: Pulling the box out of a yank!

Originally Posted by Aidanm View Post
Ah right cool, this was my first time going near a HD motor so was a nice learning curve.
Would have saved a lot of time and hassle if it could have been pulled while in the frame!
I know with the ulysses model you can remove the forks and rotate the engine forward without removing it. Dont know whether that was an option on your model...
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  #31  
Old 17th April 2019, 08:29 AM
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Default Re: Pulling the box out of a yank!

Delighted to see this thread. Great that you took the time and money to sort it out. i am glad i didnt try to sort it as it would be lying in bits in the shed still. hope its going well for you now
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  #32  
Old 17th April 2019, 11:34 AM
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Default Re: Pulling the box out of a yank!

Originally Posted by Aidanm View Post
Ah right cool, this was my first time going near a HD motor so was a nice learning curve.
Would have saved a lot of time and hassle if it could have been pulled while in the frame!
Thanks for taking the time to post photos and describe the process. Always fancied the idea of ridig a buell.

Good shot of the big single pin crank. Now people can understand why the harley engines vibrate so much.....
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  #33  
Old 17th April 2019, 12:41 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Originally Posted by louis View Post
Delighted to see this thread. Great that you took the time and money to sort it out. i am glad i didnt try to sort it as it would be lying in bits in the shed still. hope its going well for you now
Thanks man, I was hoping you'd see the thread and know she's sorted.
Running perfect now so just enjoying spins on it, next is the few cosmetics like repainting wheels if I ever get to that.
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  #34  
Old 17th April 2019, 03:24 PM
DavyH DavyH is online now
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Default Re: Pulling the box out of a yank!

Did you check the tracks on the selector drum for wear?
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  #35  
Old 19th April 2019, 03:35 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

Originally Posted by DavyH View Post
Did you check the tracks on the selector drum for wear?
I did, no smoking gun there either just a very small bit of wear.
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  #36  
Old 19th April 2019, 03:39 PM
Aidanm Aidanm is offline
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Default Re: Pulling the box out of a yank!

last couple of random shots...

Managed to drill out and save the threads on the broken stud with a lot of patience.
Click the image to open in full size.
Scavenge and pressure oil pumps.
Click the image to open in full size.

Job done
Click the image to open in full size.
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