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Author Topic: 4 speed inner cover removal  (Read 1532 times)

Afro Samurai

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4 speed inner cover removal
« on: July 25, 2013, 09:46:57 PM »
Man...this thing is stuck on good...any tricks?

I have been heating it with heat gun...will rotate..but just wont separate...all fasteners are off...main shaft nut is off...

No good prying positions..been hammering fron opposite side jus behind the fill plug...no luck....stupid cover....

Removed kick shaft retaining bolt by mistake...didnt need to...apparently I have some design change pete snidal spoke about...but removed the bolt before I read that statement...nithing feels jamed...main shaft actually moved in and out...stupid cover just wont come off...

2001 4 speed...

ERC

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Re: 4 speed inner cover removal
« Reply #1 on: July 25, 2013, 09:55:59 PM »
Are you sure you have all the screws out ? There's one behind the shift mechanism.  ERC
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

t120rbullet

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Re: 4 speed inner cover removal
« Reply #2 on: July 25, 2013, 10:40:28 PM »
Are you sure you have all the screws out ? There's one behind the shift mechanism.  ERC

That flat head that gets a glop of grease on it and you can't see it.
1999 Enfield 500 Black Deluxe "Silver"
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2013 Royal Star Venture S  "Jelly Roll"

Afro Samurai

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Re: 4 speed inner cover removal
« Reply #3 on: July 25, 2013, 10:56:38 PM »
Yep...got that one also ....hmmmm...bigger hammer?...more heat?...mainshaft moves indep of the bearing...so it isnt stuuck there....im lost

Afro Samurai

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Re: 4 speed inner cover removal
« Reply #4 on: July 26, 2013, 12:04:49 AM »
Pic....

t120rbullet

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Re: 4 speed inner cover removal
« Reply #5 on: July 26, 2013, 01:09:04 AM »
Pic....

Looks like your there. Maybe someone put some gasket sealer on there and glued it on.
Try a pry bar and a small block of wood off the frame rail. That casting will bend and/or crack pretty easy so don't get too aggressive on it.
1999 Enfield 500 Black Deluxe "Silver"
2012 Concours 14 (no name yet)
2013 Royal Star Venture S  "Jelly Roll"

mrunderhill1975a

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Re: 4 speed inner cover removal
« Reply #6 on: July 26, 2013, 03:21:25 AM »
STOP!!!!!!! Do not bash anything with the hammer.  You must unscrew the detent plunger.....to do this loosen the lock nut, then count the number of half-turns of the screw plunger.  The screw of the detent plunger threads into the gearbox case and that is what is holding inner cover onto the case.  By counting the number of half turns, you will be able to correctly adjust the preload when you put the box back together. 

Get Petes manual and follow the instructions he has.

Or you can log onto the Hitchcock tech section and there is a 5 part description for the Albion gearbox rebuild. I believe part 3 has the description of the removal procedure for the detent plunger and inner cover. (http://www.hitchcocksmotorcycles.com/technical-notes)

(see picture 9 of part three of the gearbox rebuild).
« Last Edit: July 26, 2013, 06:28:47 PM by mrunderhill1975a »

Arizoni

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Re: 4 speed inner cover removal
« Reply #7 on: July 26, 2013, 03:35:12 AM »
Is that the screw with the locknut on it that I see in the upper right in the picture?
Jim
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mrunderhill1975a

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Re: 4 speed inner cover removal
« Reply #8 on: July 26, 2013, 03:59:41 AM »
Yes, that is it in the upper right side. See the photo below.
« Last Edit: July 26, 2013, 04:12:45 AM by mrunderhill1975a »

t120rbullet

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Re: 4 speed inner cover removal
« Reply #9 on: July 26, 2013, 10:06:08 AM »
STOP!!!!!!! Do not bash anything with the hammer.  You must unscrew the detent plunger.....to do this loosen the lock nut, then count the number of half-turns of the screw plunger.  The screw of the detent plunger threads into the gearbox case and that is what is holding inner cover onto the case.  By counting the number of half turns, you will be able to correctly adjust the preload when you put the box back together. 

Duh,, talk about not being able to see the trees through the forest.
1999 Enfield 500 Black Deluxe "Silver"
2012 Concours 14 (no name yet)
2013 Royal Star Venture S  "Jelly Roll"

Afro Samurai

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Re: 4 speed inner cover removal
« Reply #10 on: July 26, 2013, 06:22:10 PM »
Ha ha...   thanks...I must have missed that statement...I will try it in a few mins...and give an update...you guys are the best...prevented a major foul up...slow and steady...

Afro Samurai

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Re: 4 speed inner cover removal
« Reply #11 on: July 26, 2013, 06:33:14 PM »
Ok  mr underhill...froto...you saved my marriage....where do I send your ring?...ha..ha...thanks for the help...can crack on now...

Afro Samurai

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Re: 4 speed inner cover removal
« Reply #12 on: July 26, 2013, 07:52:48 PM »
Small crack at thin section on inner cover bearing location...anything to be concerned about?..noticed it after removing all the grease...maybe during factory install....seems so small....moving forward..
..

mrunderhill1975a

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Re: 4 speed inner cover removal
« Reply #13 on: July 26, 2013, 08:09:32 PM »
Hmmm........"anything to worry about"....Hmmmm.  Below the crack there appears to be a wedge of metal missing, is that true or is that an optical illusion?

After looking at it more closely, I see that the wedge portion is where the shift lever (where it attaches to the ratchet mechanism) smacks the bearing holder during a violent quick-speed up-shift.  It looks as if the crack is from the outside in toward the bearing rather than from the bearing trying to break free from the bearing seat.  If you are not planning on racing this bike, I would just leave the crack alone and monitor it each time you replace a kick start spring or kick start pawl.

Send that ring to fires of Mount Doom!
« Last Edit: July 26, 2013, 08:25:58 PM by mrunderhill1975a »

ROVERMAN

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Re: 4 speed inner cover removal
« Reply #14 on: July 26, 2013, 08:47:06 PM »
Possibly a light smidge of JB Weld?