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15-12-2016 Sportster shift problems, XB12 Bigbore

2-1-2017 - 15-12-2016 Sportster shift problems, Buell XB12 Bigbore start stripping

customer had a little hap with the bike, damaged the primairy cover, mounted him self.. but it just not work right, aske me to have a look

as i can shift, but the lever is not returning,i think the shoft axle is bent ?

and the clutch is adjusted completly wrong

the mechanisme was screwed way to tight , only need to bottom lightly

no seal ? on the axle shaft

douse not look bent

drained the oil to remove the cover... but it is very hard to remove , the cover douse not slide well on the shaft

it is straight , that is not the issue

so hole in the cover to small taking some mesurements

trying with a other shifter... yup way to tight

testing... yep nce spring action again on the shlft lever

so seal on

and mounting the cover back

adjusting... lightly toughing the spring.. than back up 1/4 turn

crap seal ring that came with the cover.. i will mount a OEM one.. these fit much better

and will stay on while mounting

adjusting the cable adjsuter

and checking the primairy chain..

ready to go..

XB12S ... ready for a rebirth.. engine overhaul and making it 88 CI

she has been around the block

i think i will not mount these back ;-)

tell tail signs off worn piston rings if you have a allot off oil in the airbox

she has some nice goodies on already

wich screw again to mount , below the F and about the S

belt tensioner off

exhaust off

draining the cases right away

and the swing arm oil tank

shifter parts off

and primairy cover off

clutch basket, if you have it off, check the hub bearing... easy to check as you can pull out the hub with plates and all

years off clutch plate wear acumilated on the bottom off the cases

electics disconnected

and making space to get the the swingarm axle

oil lines off , use two spanners

for the oil line front side best to take the oil filter off

so you have better clearance to the nuts

W-Brace off complete with oil cooler and regulator

feed from the startermotor loose , and cables out the way

support the engine to remove the front mount

been there before, so after loosening, can take it out by hand

and front mount off the head

header off

and putting caps on the feed and return oil line to the swing arm

pull out the gearbox breather hose out the guide

pinch bolt loose for the swing arm

support the engine fully

swing arm axle loose

and take the weight off the bike with a hoist

so we can remove the rear engine mount bolt

and swing arm axle out

separation is a fact...

strap the swing arm to the frame, using protection not to damage it , engine to the side and the rolling chasic can be parked in a front wheel holder

now taking down the engine

manifold off

and coil bracket off

good to see the o-rings did there job ( our intake flange sollution )

rear engine mount need to come off, this is a pain, and you will need cut off allen keys , trying with ball end key will damage the bolts and slip

rocker box cover off

and evenly loosen the rockerbox

head to follow

looks good with so many km done, good fuel mapping will do that ;-)

and the front off..

head bolts can take some force to loosen these

drilling off the timing cover plate

marking the pick up for easy mounting back, as we are going to overhaul the crank, we need to check it , but this is ok for start

take the connector from the sensor to take it out the cover

pick up cup removeal

the cam covers can be sticking on very hard.. gently looking for flats to have a lever point , and a little tap can work

very slight markings on the cams

but oil pump gear ( old model ) looks still good..

push rod covers..

pulled the cylinder off , hone markings are about gone

looking at the 2e compression ring , this is shiny for the most part... sign off the rings are worn out

other cylinder same story

crank big end is nor broken or any, it feels very loose , piston pins have to much play ( the noise the engine made )

i will replace the gearbox bearings to as the leak markings on the seal tells me the bearing has a little to much play

locating pins for the lifters out

these look still decent