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11th February 2021
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XL FORUM TEAM MEMBER
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Join Date: May 2020
Location: Lower AL
Posts: 186 Sportster/Buell Model: XL 883 Sportster/Buell Year: 2007 Other Motorcycle Model: Suzook Burgman 400/ 2008
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Recap of my tranny repair
2007 883 Just bought Memorial Day 2020
10,000 actual miles!? Yes.
As you might know, on Sept 7 I broke off the end of the mainshaft. Hmm an impact driver is NOT the best tool sometimes.
So I ended up installing a new mainshaft myself, after a few hundred questions on this site. I couldn't find anyone who would press the shafts out.
I bought a H.F. 12 ton press  Also, a $10 FSM on-line. Best $10 I spent.
THE BIKE IS BACK ON THE STREET! Runs fine.
Cost of parts, about $500? I think shipping total was about $100.
New Drag Specialties motor mounts about $100.
Replace clutch spring disc with 3 plates about $100 I forget the actual price.
UH OH gas tank RUST- New fuel nozzle $53, Kreem kit about $60.
Misc sockets, and plumbing parts, for press tools about $50 total.
Add engine oil and trans oil.
Thanks to this forum. Also Ronnie's. Note, some parts deliveries took a while, COVID or holidays I guess.
Press, about $130 
Hardest parts of this job (I'm no expert here....):
I wouldn't use the Harley RTV again. I've used GM RTV on my Saturn, it was much easier to use. The H.D. stuff was really thick and hard to work with.
You don't need a jig to hold the 2 trans shafts when pressing. Just zip tie them together and press each a LITTLE at a time, either in or out.
Installing the piston pin CLIPS was a PAIN.
Installing valve springs was difficult. I made my own compressor.
Glad I could fix it myself
Next jobs:
Install 30T sprocket
Make and install luggage rail
Now to put some miles on her 
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11th February 2021
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 617 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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Nice recap. Glad it all worked out.
__________________
'54 KHK (Current Build), '13 XL”72” Hard Candy, '97 Honda Valkyrie. I’m Retired 🥃
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11th February 2021
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Senior Master Custom Bike Builder
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Join Date: Apr 2012
Posts: 3,712 Sportster/Buell Model: XLH 883/1250 Sportster/Buell Year: 1991
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Quote:
Originally Posted by Mike1nw
Installing the piston pin CLIPS was a PAIN.
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I agree.
John |
12th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2009
Location: In a swamp/Michigan
Posts: 15,128 Sportster/Buell Model: XL1460C Sportster/Buell Year: 2000 Sportster/Buell Model #2: XL1200R Sportster/Buell Year #2: 2006 Other Motorcycle Model: XL1200R Other Motorcycle Year: 2004
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We’ll get back to bonding, happy that you were able to get her done yourself!
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25th February 2021
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XL FORUM TEAM MEMBER
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Join Date: May 2020
Location: Lower AL
Posts: 186 Sportster/Buell Model: XL 883 Sportster/Buell Year: 2007 Other Motorcycle Model: Suzook Burgman 400/ 2008
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Took it out for a half-day ride. Grin-inducing. |
25th February 2021
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Senior Master Custom Bike Builder
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Join Date: May 2010
Location: Pottstown PA.
Posts: 14,509 Sportster/Buell Model: xlch Sportster/Buell Year: 1960
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you've done quite well then.
__________________
72 1000cc barrels and heads, s&s 41/2'' flywheels, sifton cams, s&s super B w/ zippers thunderjet w/yost powertube, andrews gears,and shafts, competition engineering kevlar wet or dry clutch, 72 oil pump, morris magneto w/auto advance and single fire module, cycle electric generator w/electronic regulator,73 cu.in.
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