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Old 03-21-2012, 06:48 AM   #76
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Originally Posted by KneeDrachen View Post
Crap, I don't think I can make 1PM. I missed the Mt Royal Tavern get -together, too, looks like. That used to be my haunt, when I was a young miscreant...
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Old 03-23-2012, 06:56 AM   #77
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If you can dig up pics, I'd be really interested to see them. This side-valve stuff is addictive!
I think I just have to be less gentle with the transmission. Did you use any lube on the clutch shaft? On the BMW airheads some people recommend honda moly or white lithium grease (just a tiny bit). I actually dressed the clutch plate slots with a fret file and still they get hung up on little burrs, either in the slots of on the shaft. These parts are ruff!
Looks like I don't have any closeup pictures of the engine/drivetrain restoration available..just overview pictures.

I didn't need to use any lube on the clutch shaft, I guess the clutch plates are worn enough to fit easily:)

When we picked up the K-750, Eva is looking at her "new" bike:
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Old 03-23-2012, 08:32 AM   #78
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Originally Posted by arcticIndian View Post
Looks like I don't have any closeup pictures of the engine/drivetrain restoration available..just overview pictures.

I didn't need to use any lube on the clutch shaft, I guess the clutch plates are worn enough to fit easily:)

When we picked up the K-750, Eva is looking at her "new" bike:
Looks good.
The lube isn't to get the gearbox on more easily. It prevents wear of the splines during normal operation.
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Old 03-23-2012, 08:37 AM   #79
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Looks good.
The lube isn't to get the gearbox on more easily. It prevents wear of the splines during normal operation.
Right- I get that, although it can't hurt getting the tranny installed. I ask because there's a big debate about the use of lube on the clutch shaft among airhead nerds. Some say yes, others consider it verboten, because it isn't in the manual.
I find a little lube is never inappropriate.
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Old 03-23-2012, 08:44 AM   #80
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Yowzaa!

Quote:
Originally Posted by arcticIndian View Post
Looks like I don't have any closeup pictures of the engine/drivetrain restoration available..just overview pictures.

I didn't need to use any lube on the clutch shaft, I guess the clutch plates are worn enough to fit easily:)

When we picked up the K-750, Eva is looking at her "new" bike:
Eva looks a little trepidatious....

That looks like a well appointed shop, Arctic! Is that an automobile lift?
What else you got in there?
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Old 03-23-2012, 09:00 AM   #81
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I find a little lube is never inappropriate.


LOL!!
And of course... Never use a non-oem piece, or a non manual reccomended procedure on an airhead!
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Old 03-23-2012, 10:06 AM   #82
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I find a little lube is never inappropriate.
That's what she said. . .


What speed shop are you using?????
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Old 03-23-2012, 11:44 AM   #83
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That's what she said. . .


What speed shop are you using?????
http://www.jbsautomachine.com/

These guys were great. Ask for Jerry.....
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Old 03-23-2012, 11:58 AM   #84
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Ok, back to work!

With the motor destroyed it was time to pull the transmission apart. The kickstarter wasn't working, and it had a quart of water in it, so I knew it would need to come apart. At one point not long ago I never would have attempted this, but I managed to turn the motor into little pieces, so how hard could the transmission be?

I started on one side and worked my way around. First the foot shifter:



The backside of that captures this notched gear type part.......



.........which is on the end of a rod that passes through the box to this thing, which is what actually switches the gears, by pulling the shift forks back and forth, which engage the gears with different gears on the mainshaft. See the rounded notches on the right edge? 1st at bottom, then 2nd, 3rd, and 4th, way up top.

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Old 03-23-2012, 12:21 PM   #85
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All the guts come out this trap door in the front of the transmission, once the shifter parts are removed.



The whole thing was full of this baby poo mix of oil and water. I stank like a cat-box.



Once that's opened up, it's a matter of removing bearings and gears from each shaft alternately, until each one can be pulled out of the rear bearings as a unit.





That big gear above with the spring on the shaft is the kickstarter gear.

Here's the kickstarter ratchet return mechanism.


Finally it was gutted and the organs laid out for inventory. All the bearings were shot- one I couldn't even turn, it was so corroded.

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Old 03-23-2012, 04:01 PM   #86
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Wow, that is a pretty simple transmission. I think the 3-speed in my pickup has more parts in it. XD
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Old 03-23-2012, 04:08 PM   #87
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Wow, that is a pretty simple transmission. I think the 3-speed in my pickup has more parts in it. XD
Yeah, not much too it. The kickstart gear and shaft is missing from that photo, but that's it otherwise.
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Old 03-23-2012, 06:43 PM   #88
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That's going to be an awesome bike when you get it running. I have to admit to being just a shade jealous. ;P
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Old 03-26-2012, 12:22 AM   #89
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Eva looks a little trepidatious....

That looks like a well appointed shop, Arctic! Is that an automobile lift?
What else you got in there?
This is my friend's (the guy on the right) motorcycle repair shop, my own hobby garage/ shop is somewhat smaller:)
They use the lift for working on cars, and sometimes lifting sidecar rigs.
He picked up Eva's K-750 with a load of parts, the seller didn't want to sell the parts without the bike. So we bought the K-750.

I wouldn't use excessive amounts of lube on the transmission input shaft, excessive lube may end up on the clutch friction plates. It looks like the centers of the friction plates are made of a much softer metal, to reduce the wear on the splined shaft.
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Old 03-26-2012, 05:45 PM   #90
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Motor and transmission were apart, all the bearings and seals ordered, and the cylinders were at the machinist's shop. I had intended to use the one-over Russian pistons that came extra with the bike, but that was a no-go. The machinist called to say the cylinders were pitted pretty badly. Not only that, they were severely out of round. Bottom line- in order to make the bores symetrical and eliminate the pitting they would have to take out too much material to use the surplus pistons. So, Plan B.

It was recommended by a friend Scooter Bob to check these out:

http://www.kb-silvolite.com/silv-o-l...tails&S_id=363



They were for old Nissan tractors or something. Scooter Bob owns his own Dnepr M72H and used to import and rebuild Chiang Jiangs. He had used them successfully in a few of the CJs. Since they were cheaper than a second set of Russian pistons and I could get them immediately, I bought a pair, along with a set of Hastings rings. One glitch was that the distance from the top of the wrist pin to the crown was less than the stock pistons, which meant I would lose some compression. Jerry the machinist assured me he could skim the outer edge of the cylinders enough to compensate. One good thing is because they're not made out of melted down pots and pans and Trabant hubcaps, and so wouldn't expand as much as the OEM pistons, I could get away with a tighter bore clearance than the .006" they say to use with the Soviet slugs.

Jerry the machinist really took an interest in the project. He called a number of times to see what I thought of this and that- he had his own ideas about how to make the motor reliable and efficient, and I just let him go with whatever he thought was best. I guess it was fun for him having something besides another small block Chevy to overbore. Finally he called me and said it was all ready to go. I went and picked it all up in my airhead rig. All the dudes in the back came up front to check that out and see the parts off. It was pretty funny. I hope I'm able to get this thing back together so I can ride it over there and show them what all the work was for!


They cleaned the case in the sonic cleaner. Not sure how that works, but it was easier than scrubbing it myself..




The cylinders and valve covers had been bead blasted and looked velly velly niize..



New springs and a triple-cut valve job..


Nice crack there, huh? What a kick in the gut. Hopefully that will be OK. There's a video on YouTube that shows an M72 running with much worse damage:

http://www.youtube.com/watch?v=Ljs5rhBy7Hk

http://www.youtube.com/watch?v=r3SSgIEI4PE

Holy smokes!

The new pistons had had to be machined to accept the circlips that hold the wrist pins in. They even gapped and installed the rings for me.



Meanwhile the SKF bearings and seals I ordered had come in, so no excuses- I had to start putting it all back together!
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