HarleyTechTalk

Okay- Tranny's out. I want to fix my speedo that I've never been able to make work. My suspicion is the aftermarket case has a thicker wall and impedes the drive from spinning freely- Once it stops the wing geat just wiped the aluminum teeth off the drive. To get to this with a dremel though will require complete disassembly though.

Had many other trans apart (cars, trucks) but never one of these. Can this be done with my normal "good" complete set of tools? Any specialty items needed? once apart, everything goes back in in reverse- any reason to change and shifting adjustments provided nothing was changed inside?

Asking for any shortcuts also since everything is good and nothing needs replaced. All I have to do is clear the case to allow for the machining. I'm a decent mechanic, having done everything else incuding the motor- just never tore into the trans- didn't discover this issue till it was all together and I was riding-

thanks in advance!
Greybeard

YUP you got it pretty well covered. Follow the procedure in the manual and you should have no problems. It's pretty tight in there. Nothing should change if it's just remove the gearset, clearance and replace the gearset.
EASY

Make sure you have matching gears for that speedo drive. It does exist at least 2 different ones that will eat each other if not matching.

xlfan

On the topic of different gear sets- yeah- I know about these. I'm using the correct drive. Thru modifying the gear on the drive (filing away the square ends and making it almost a a "round" profile) I did succeed in getting almost 150 miles out of one gear- still, it's not right and I want it right. As much as I like my cool little bicycle speedo and it's done a great job, I have this brand new speedo in my dash just sitting there as an ornament!

It COULD be that the "coarse" gear set would be a better choice while in there but that would also require another speedo since then I'd need the 1:1 ratio.

Thanks for throwing this possibilty out here though!

Greybeard

Well, the suspicion of the pinion on the speedo drive hanging up on the case wall was correct. It's clearanced now, should work just fine. More to come in the way of questions, though as I go thru the tranny and seek out cures to other trouble spots. Stay posted.

thanks!
Greybeard

Also found (once the countershaft was back in place) that the helical cut speedo ring gear pressed onto the gear was NOT in the correct position. It must be square on the center of the "land" there. It's just pressed into place so it's an easy fix. That aligns it perfectly with the speedo drive.

All this may sound like overkill but I got alot of this stuff as a basket originally and just made assumptions about things being correct- they weren't. Hope some of this may help others sort out issues rather than just doing without a speedo.

Greybeard