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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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Old 4th October 2007
Rudy2 Rudy2 is offline
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Join Date: Aug 2007
Posts: 130
Sportster/Buell Model: XLH
Sportster/Buell Year: 1982
Sportster/Buell Model #2: Triumph T140
Sportster/Buell Year #2: 1979
Other Motorcycle Model: Norton Commando
Other Motorcycle Year: 1972
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Default Trans rebuild questions

Well, I have bought replacements for my water damaged primary drive and transmission and will be reassembling my "bargain" '82 soon. I have a background in this sort of work and a factory manual so I am almost ready to go. One thing that is different about this trans is the oversize roller thing. This is pretty unusual but apparently there are several roller sizes to choose from for setting up the output bearing. How do I know what size roller to use? I must need to know diameters of the shaft bearing surface and outer race I.D. as well as clearances. Anyone know about this?

Randy
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Old 5th October 2007
BuckIRyder BuckIRyder is offline
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Join Date: Jun 2006
Posts: 2,463
Sportster/Buell Model: XLCH
Sportster/Buell Year: 1972
Other Motorcycle Model: Heritage Softail
Other Motorcycle Year: 1999
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You are right on track Randy, you need the shaft O.D. and race I.D to size the rollers. Oversize rollers are manufactured to achieve correct fit in worn races. If you can see obvious wear. scoring, pits, etc. the race must be lapped to remove these indications. Believe there is a special lap sold by Jims Machining for this, probably not cheap. Once lapped, the roller size is determined based on the measurements and clearance required. Strongly suggest you refer to the factory manual for this procedure.
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