The fun has begun (JOG installed 5/2)

[minst7877]

Well I finally jumped into the fire and stared the maintenance that I wanted to do this winter. So far I have been pleasantly surprised at how well things are going. I had the bike on the lift table and put my jack adapter on the bike and put a table jack under the frame to stabilize the bike and get the pressure off the rear wheel.

Today 2/28 I did this
Pulled the bags and bag brackets.
Removed both mufflers and rear head pipe.
Removed rear brake and pulled rear wheel. New tire to install
Drained and removed final drive. will flush and refill with syn oil
Removed swingarm and drive shaft.

Bike had 23000+ miles on it when we bought it last year and from what I am seeing so far someone has taken pretty good care of her.
Surprised to find that the grease on the swingarm bolt and spacers wasn't completely dead and lots of grease in the drive-shaft splines.
U-joint could use a little work as one axis is a little stiff.
Time spent today 2 hours.

DC

[AlabamaNomadRider]

Sounds like the previous owner took good care of it.

[ringadingh]

Seems like you got a fair bit done in a couple hours.

[minst7877]

What can I use to flush out the final drive that won't contaminate the new oil when it goes in? It has been laying inverted with both plugs out draining since yesterday morning. Went over to the local Kaw dealership today to check on some parts and Ma Kaw isn't letting them order anything right now. I also noticed there were no new Kaws on the floor. Doesn't give me the warm fuzzes wanting to deal with them.

DC

[ringadingh]

I wouldn't bother flushing it, if you leave it draining overnight you will get everything out. There isn't much in there to create a pile of mung. Just refill it and your done.

[chuckster131]

May need to hire you to do some maintenance on my Nomad

I did manage to get the fairing off so far, but I need to replace the front tire and also I'm replacing the front and rear wheel bearings and seals too..... Need a oil change as well

[minst7877]

Thanks Steve will do that.
Joe somehow you don't come across to me as someone who would let anyone else work on your ride.

DC

[chuckster131]

[quote Joe somehow you don't come across to me as someone who would let anyone else work on your ride.

DC[/quote]

Sure I would........... ::)

[minst7877]

Today
Right front floor board and bracket removed
Front head pipe
Have all bolt loosened and ready to come out of side frame rail.
Regreased u-joint works slick now.

How much play can we have side to side in the swingarm before we need to replace seals?
Joe I sent you a e-mail

DC

[minst7877]

Got my parts Swingarm seals, Driveshaft boot, Clutch Cover gasket and mean streak clutch spring. Also a set of HD exhaust gaskets. So its back to work on the bike.

Swingarm, driveshaft cleaned, inspected, regreased the U-joint and all shaft splines with a moly grease. New rear tire mounted and balanced. Swingarm bearings, spacers and bolt cleaned and relubed with a waterproof bearing grease that I use on the boat trailer wheels. Have reassembled and torqued all bolts to manual specs. Rear bag support reinstalled and checked the status of the rear brake disc pads. Still have at least 50 percent of their life left. Refilled final drive with full synthetic 80 - 90 gear oil.

Next weeks project is to pull the clutch cover and check the clutch spring, fibers and to see if it still has the plastic oil gear and will go from there.

DC

[minst7877]

Well the clutch cover came off yesterday and today I need to get a hold of Judge It still has the POG and the teeth are worn down to sharp points of plastic. Clutch looks good but will have to deal with the proud metal on the back of the basket before it goes back together. It will go back together with a set of Judges washers and a mean streak spring.

Need to get busy as my DR finally gave me a date that I can start riding again. Got to have it ready for the 1st of May

DC

[ringadingh]

I wouldn't gamble riding it with the pog in it, that plastic is old and brittle after all these years and it won't take much to finish it off. Id also replace the clutch spring with a Meanstreak spring while your in there. The springs cost about $20.00 or so and are easy to replace.

[minst7877]

Already have the new mean streak spring and cover gasket. It will not go back together in its current condition. McMaster Carr dropped off a package today that had a couple of fittings and a pressure gauge in it. I will know at a glance what air pressure is in my shocks and they will both be exactly the same.

Talked to Bob Oglesby "Judge" today and will have a new gear on the way soon.

DC

[ringadingh]

When your installing the new oil gear make certain that you clean the area that requires the loctite religously to make sure there is no trace of oil to be found. You don't want the shaft to come loose at a later date because of a sloppy cleaning job during assembly.

[minst7877]

Back to work on the bike this evening as I received a package in the mail from Judge. Read the revised directions that he sent me and was glad I hadn't pulled the old gear off before reading the new instructions. Got out the dial indicator and checked the end play on the old gear and this measurement needs to be the minimum dimension for end play once the new gear is installed. Old gear had .028 thousanths inch end play. I then plugged the case holes to the oil sump and drilled holes thru the plastic gear. Twisting a screw driver I put pressure on the gear until it split apart and fell off the shaft. The keeper then needs to be trial fit to the shaft after getting all the little bits of plastic cleaned up. I was lucky and the keeper started onto the shaft easily and then tightened when about half way on. I put a little pressure on the keeper with my thumb and fore finger and it snapped into place on the shaft. The gear slid right on over the keeper so I put the two bolts in and checked the end play. With the new gear installed I had .040 end play which is more than the original so we were good to go. Face runout was only .004 thousandths so that is good. Disassembled the gear cleaned all parts with acetone and applied the locktite and reassembled. Clutch reinstalled with a mean streak spring. Soaked the cover gasket in trans fluid and reinstalled clutch cover. Frame section back in with everything connected. Just need to get the exhaust hooked back up and all the chrome covers. Hope to be riding by the end of the week.