celebrate, celebrate,,,dance to the music

**Idaho** · 03-05-2011, 07:40 PM

The deed is done. New cam chain extenders are installed. 2007 Nomad with almost 40,000 miles on the fun meter. The engine was very NOISY. I bought the extenders from Joe (Chuckster) about six months ago. Then I ordered new gaskets. And took my time to get a 5mm hex wrench with a ball end on it. Get the picture? I was in NO hurry. Printed off the instructions from Gadgets page and read them 5 or six times. Seemed confusing to me.

Well, spring is sort of in the air and I want the bike to be ready for riding season so I decided that today was the day. I started out by sweeping out the garage and took the Nomad for a short spin into town to warm up the engine. Then I rolled it into the garage and started on the back cylinder. I decided to do it with the exhaust pipe still connected. It worked.

I gotta tell you, once you get the little beast out and start to mess with it it's pretty obvious how it works. Don't be afraid of that part of the job.

The only vise that I have is a cheap drill press vise that I bought from Harbor Freight. That worked great to hold the old extender tight enough for me to use a hacksaw to spit the old ring. Never even marked the shaft underneath. Joes extender replacements fit on perfectly. I put a drop of red loctite in the cup and pushed it into place then used a paper towel to carefully clean up the overflow as it oozed out from under the cup. I let it set up for a few minutes and assembled the spring and bearing retaining ring in the other end. It all went together easilly and when I backed out the small retaining screw the unit inside snapped into place like it was supposed too.

The front one was a bit more of a challenge. I still have a stock intake complete with a crossover tube. That POC will go one of these days when I can get Chucksters intake kit. In the meantime I had to deal with it. That meant completely loosening the intake plates on both sides of the bike. Beware, there are four small square nuts sitting in slots in the end of the crossover tube that WILL fall out onto the floor. Watch for them.

Oh, on my left side intake the 8mm bracket bolts would not come out easilly. Rolled off the edges with a 12 pt socket on the front one so I drove to town to get a nice six point 8mm socket. The rear bolt came out, the front one just rolled off the shoulders again. I'm trying not to panic at this point because I needed to get the last extender done and I needed to get my intake back together. I grabbed the bracket that the offending bolt was holding down and bent it out a little ways and twisted it and lo and behold the bolt with the rounded head turned. I put the six pt socket back on it and it backed out without any problem. Luckilly I found two small bolts to replace the damaged ones with so I was happy.

I figured out that I was not able to remove the inside screw because the cap on the extender body was in the way of the hex key shaft and prevented me from turning the screw. So I took the cap off and pulled out the springs and laid those pieces on the workbench. Then I was able to remove the rear screw and then the front one. Getting the extender body out with the crossover tube in the way was a challenge. I found that by rotating the extender body I was able to find a spot where it practically fell out.

I reassembled it without the cap and spring installed so that I could get the back screw in and tight. It worked and I was able to get the cap screwed back on without too much trouble. Keep in mind that I had to compress the spring inside under the cap and turn the cap until it threaded onto the extender body.

All in all it was not too bad of a job. A little time consuming.

When I hit the starter button it was amazing to me how quiet the engine is now. My back extender was all the way bottomed out and the front only had a few clicks left. This made a lot of difference. Glad that I finally got it done.

mikeyger · 03-05-2011, 09:25 PM

Bud I remember a few months ago I said the anticipation is worse than the job! I was just like you and now when you look back it is not hard at all. Like your rounded bolt I always seem to have more trouble with something I did not even consider was going to happen, something minor.Congradulations !First day of spring is only 16 days away! Becareful!

VulcanE · 03-05-2011, 09:31 PM

Congrats Bud on a job well done. When I did mine, the front cylinder was easier to do than the rear cylinder was, but I don't have the cross-over tube in the way. When I did DK's it was almost exactly as you described.
I only had 3 clicks left on both my tensioners, On DK's he had 3 clicks left on the rear, and 5 on the front. Like you said, it is amazing how much quieter the engine gets.

Netnorske · 03-05-2011, 10:24 PM

Good job Bud! I was glad to get mine done too, just for the peace of mind. The weather here has sucked, but getting a ride in now and then. Tomorrow I'm meeting a couple other members for a scoot as it is supposed to be sunny for a change!

**Cajunrider** · 03-05-2011, 10:40 PM

Nice job Bud. You'll have peace of mind not worrying about those anymore.

**ringadingh** · 03-05-2011, 11:09 PM

Mine doesn't have the crossover tube so it wasn't that bad to do at all. Both adjusters were out of travel. I did one with the crossover tube installed and it does teach you a few new words in comparison.

**Idaho** · 03-05-2011, 11:35 PM

You guys are all correct. The anticipation was far worse than the actual job. Those things really are easy to figure out. I can't believe how much quieter the engine is now. Really amazing.

My next task will be to change out the clutch and brake fluid.

**ringadingh** · 03-05-2011, 11:49 PM

Quote:

Originally Posted by Idaho (High Plains Drifter)

You guys are all correct. The anticipation was far worse than the actual job. Those things really are easy to figure out. I can't believe how much quieter the engine is now. Really amazing.

My next task will be to change out the clutch and brake fluid.

And that is even easier Bud. ;)

AlabamaNomadRider · 03-05-2011, 11:49 PM

Good job Bud. I know you are glad to have that out of the way.

mikeyger · 03-06-2011, 07:34 AM

Bud We must be on the same page .The fluid change was what I did next and it is even more simple. It took me a little longer because of the chrome rotor covers on the front wheel. keep up the good work. In a couple of months I am going to tackle the swingarm maintenance when I change my back tire.Care to join me!

**Cajunrider** · 03-06-2011, 08:37 AM

Quote:

Originally Posted by Idaho (High Plains Drifter)

You guys are all correct. The anticipation was far worse than the actual job. Those things really are easy to figure out. I can't believe how much quieter the engine is now. Really amazing.

My next task will be to change out the clutch and brake fluid.

Make it easy Bud.....get yourself a Mity Vac hand vacuum pump to change the fluids.

**Idaho** · 03-06-2011, 10:17 AM

Quote:

Originally Posted by mikeyger

Bud We must be on the same page .The fluid change was what I did next and it is even more simple. It took me a little longer because of the chrome rotor covers on the front wheel. keep up the good work. In a couple of months I am going to tackle the swingarm maintenance when I change my back tire.Care to join me!

I'd love to, when can you get here?

Did my swing arm last year when I mounted my CT. That was easy. Just had a lot of parts off the bike was all.

ballast · 03-07-2011, 01:09 AM

Good going Bud.
It has all been easier in hind sight. My tenioners were about out of play. I can't wait to get it fired up to see how it sounds. Of course I have new pipes and chuckster intake so the sound should be really different. And it's gonna be lit up like a christmas tree.

**Idaho** · 03-07-2011, 07:58 AM

[quote=Cajunrider ]

Quote:

Originally Posted by "Idaho (High Plains Drifter)":immi965p

You guys are all correct. The anticipation was far worse than the actual job. Those things really are easy to figure out. I can't believe how much quieter the engine is now. Really amazing.

My next task will be to change out the clutch and brake fluid.

Make it easy Bud.....get yourself a Mity Vac hand vacuum pump to change the fluids.[/quote:immi965p]

Mitch, I assume that hand pump pulls fluid from the system via the bleed valves on the brakes through a flexible hose. Where do you connect on the clutch hydralic system?

VulcanE · 03-07-2011, 08:43 AM

[quote=Idaho (High Plains Drifter)]

Quote:

Originally Posted by "Cajunrider ":gq0ipph0

Make it easy Bud.....get yourself a Mity Vac hand vacuum pump to change the fluids.

Mitch, I assume that hand pump pulls fluid from the system via the bleed valves on the brakes through a flexible hose. Where do you connect on the clutch hydralic system?[/quote:gq0ipph0]

I'm not Mitch, But yes Bud, it attaches to the bleeder valve via a rubber boot. On the clutch slave unit, there is also a bleeder valve. You have to remove the left side engine cover to access it.

03-05-2011, 07:40 PM	#1
Idaho Join Date: Aug 2007 Location: Pocatello, Idaho Posts: 5,241	celebrate, celebrate,,,dance to the music The deed is done. New cam chain extenders are installed. 2007 Nomad with almost 40,000 miles on the fun meter. The engine was very NOISY. I bought the extenders from Joe (Chuckster) about six months ago. Then I ordered new gaskets. And took my time to get a 5mm hex wrench with a ball end on it. Get the picture? I was in NO hurry. Printed off the instructions from Gadgets page and read them 5 or six times. Seemed confusing to me. Well, spring is sort of in the air and I want the bike to be ready for riding season so I decided that today was the day. I started out by sweeping out the garage and took the Nomad for a short spin into town to warm up the engine. Then I rolled it into the garage and started on the back cylinder. I decided to do it with the exhaust pipe still connected. It worked. I gotta tell you, once you get the little beast out and start to mess with it it's pretty obvious how it works. Don't be afraid of that part of the job. The only vise that I have is a cheap drill press vise that I bought from Harbor Freight. That worked great to hold the old extender tight enough for me to use a hacksaw to spit the old ring. Never even marked the shaft underneath. Joes extender replacements fit on perfectly. I put a drop of red loctite in the cup and pushed it into place then used a paper towel to carefully clean up the overflow as it oozed out from under the cup. I let it set up for a few minutes and assembled the spring and bearing retaining ring in the other end. It all went together easilly and when I backed out the small retaining screw the unit inside snapped into place like it was supposed too. The front one was a bit more of a challenge. I still have a stock intake complete with a crossover tube. That POC will go one of these days when I can get Chucksters intake kit. In the meantime I had to deal with it. That meant completely loosening the intake plates on both sides of the bike. Beware, there are four small square nuts sitting in slots in the end of the crossover tube that WILL fall out onto the floor. Watch for them. Oh, on my left side intake the 8mm bracket bolts would not come out easilly. Rolled off the edges with a 12 pt socket on the front one so I drove to town to get a nice six point 8mm socket. The rear bolt came out, the front one just rolled off the shoulders again. I'm trying not to panic at this point because I needed to get the last extender done and I needed to get my intake back together. I grabbed the bracket that the offending bolt was holding down and bent it out a little ways and twisted it and lo and behold the bolt with the rounded head turned. I put the six pt socket back on it and it backed out without any problem. Luckilly I found two small bolts to replace the damaged ones with so I was happy. I figured out that I was not able to remove the inside screw because the cap on the extender body was in the way of the hex key shaft and prevented me from turning the screw. So I took the cap off and pulled out the springs and laid those pieces on the workbench. Then I was able to remove the rear screw and then the front one. Getting the extender body out with the crossover tube in the way was a challenge. I found that by rotating the extender body I was able to find a spot where it practically fell out. I reassembled it without the cap and spring installed so that I could get the back screw in and tight. It worked and I was able to get the cap screwed back on without too much trouble. Keep in mind that I had to compress the spring inside under the cap and turn the cap until it threaded onto the extender body. All in all it was not too bad of a job. A little time consuming. When I hit the starter button it was amazing to me how quiet the engine is now. My back extender was all the way bottomed out and the front only had a few clicks left. This made a lot of difference. Glad that I finally got it done. __________________ Idaho (aka Curmudgeon) Blue Knights Idaho III VBA #110 VROC #24864 IBA #49753 2007 Nomad 86,000 miles Bud Smalley Pocatello, Idaho Idaho Jack Adapter Login or Register to Remove Ads
	0

03-05-2011, 09:25 PM	#2
mikeyger Member Join Date: Aug 2010 Location: hermitage tenn Posts: 410	celebrate, celebrate,,,dance to the music Bud I remember a few months ago I said the anticipation is worse than the job! I was just like you and now when you look back it is not hard at all. Like your rounded bolt I always seem to have more trouble with something I did not even consider was going to happen, something minor.Congradulations !First day of spring is only 16 days away! Becareful!
	0

03-05-2011, 09:31 PM	#3
VulcanE Sr. Member Join Date: Jan 2008 Location: Cartersville, Georgia Posts: 4,838	celebrate, celebrate,,,dance to the music Congrats Bud on a job well done. When I did mine, the front cylinder was easier to do than the rear cylinder was, but I don't have the cross-over tube in the way. When I did DK's it was almost exactly as you described. I only had 3 clicks left on both my tensioners, On DK's he had 3 clicks left on the rear, and 5 on the front. Like you said, it is amazing how much quieter the engine gets. __________________ Cliff "VulcanE" Evans 2005 Blue & Silver 1600 Nomad VBA # 320 VROC # 20381
	0

03-05-2011, 10:24 PM	#4
Netnorske Top Contributor Join Date: Aug 2008 Location: Everett, Washington Posts: 5,709	celebrate, celebrate,,,dance to the music Good job Bud! I was glad to get mine done too, just for the peace of mind. The weather here has sucked, but getting a ride in now and then. Tomorrow I'm meeting a couple other members for a scoot as it is supposed to be sunny for a change! __________________ *Kris Olsen* VBA #0691 2017 HD Ultra Limited Low 2013 Victory Cross Country Tour 2012 1700 Vulcan Voyager 2008 1600 Vulcan Nomad 1997 Vulcan 800 Classic *"Growing old is mandatory,* *but growing up is optional"* Custer 2009\|Kalispell 2010\|Cortez 2010\|Crescent City 2011\|Kanab 2012\|Canmore 2012\|Estes Park 2013\|Orofino 2014\|Lake Tahoe 2015\|Red Lodge 2016
	0

03-05-2011, 10:40 PM	#5
Cajunrider Join Date: Apr 2008 Location: (SE Louisiana) Posts: 8,340	celebrate, celebrate,,,dance to the music Nice job Bud. You'll have peace of mind not worrying about those anymore. __________________ 2016 Electra Glide Ultra Limited CVO Palladium Silver / Phantom Blue 110 cu in SE 2012 Electra Glide Ultra Limited (Traded 6/22/16) Tequila Sunrise / HD Orange Vance & Hines true dual headers Rinehart 4" slip ons Screamin Eagle Super Tuner Screamin Eagle Stage 1 intake Dyno tuned H.O.G.# 4514015 2007 Nomad 1600 (Traded 6/23/12) VBA #482 Login or Register to Remove Ads
	0

03-05-2011, 11:09 PM	#6
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	celebrate, celebrate,,,dance to the music Mine doesn't have the crossover tube so it wasn't that bad to do at all. Both adjusters were out of travel. I did one with the crossover tube installed and it does teach you a few new words in comparison. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
	0

03-05-2011, 11:35 PM	#7
Idaho Join Date: Aug 2007 Location: Pocatello, Idaho Posts: 5,241	celebrate, celebrate,,,dance to the music You guys are all correct. The anticipation was far worse than the actual job. Those things really are easy to figure out. I can't believe how much quieter the engine is now. Really amazing. My next task will be to change out the clutch and brake fluid. __________________ Idaho (aka Curmudgeon) Blue Knights Idaho III VBA #110 VROC #24864 IBA #49753 2007 Nomad 86,000 miles Bud Smalley Pocatello, Idaho Idaho Jack Adapter
	0

03-05-2011, 11:49 PM	#9
AlabamaNomadRider Sr. Contributor Join Date: Jul 2009 Location: Boaz, Alabama Posts: 13,742	celebrate, celebrate,,,dance to the music Good job Bud. I know you are glad to have that out of the way. __________________ Gene Cross, Jr. Boaz, Alabama KawaNOW/VBA #1181
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03-06-2011, 07:34 AM	#10
mikeyger Member Join Date: Aug 2010 Location: hermitage tenn Posts: 410	celebrate, celebrate,,,dance to the music Bud We must be on the same page .The fluid change was what I did next and it is even more simple. It took me a little longer because of the chrome rotor covers on the front wheel. keep up the good work. In a couple of months I am going to tackle the swingarm maintenance when I change my back tire.Care to join me!
	0

03-07-2011, 01:09 AM	#13
ballast Sr. Member Join Date: Mar 2009 Location: Orting, WA Posts: 1,394	celebrate, celebrate,,,dance to the music Good going Bud. It has all been easier in hind sight. My tenioners were about out of play. I can't wait to get it fired up to see how it sounds. Of course I have new pipes and chuckster intake so the sound should be really different. And it's gonna be lit up like a christmas tree. __________________ Charlie "Ballast" Krogh 2005 1600 Nomad "Tangerine Dream" VBA #999 VROC #29355
	0

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