Rebuilding an FXWG engine and transmission

Rodney · #1 05-11-2008, 08:12 AM

Hi guys,
My buddies 1980 80 FXWG engine died on him last week in a rather noisy way I was told [:'(].
I've been after him for a year to take a look at his 4 speed transmission thats been making horrible noises, but he kept on riding.
I wouldn't ride behind him for fear of the thing grenading in front of me but now the trans is only 1/2 his problems.
He also has a real nice rigid frame with a pan bottom shovel top which we were getting ready to work on since the engine has been broken for some time. He hasn't been in a huge hurry to do anything about it since his 80 was running. Now he has two broken motorcycles and is really bummed out. He didn't know which way to go or where to start SO I offered to help him any way I could.
I will be getting the 80 to my place today and take it apart for him and see what damage is done to the engine and take the transmission out while I'm at it.
He's awfully busy these days and I could tell he was dreading to work on his Harley. It so happened that since I finished my 68 I was a little bummed I didn't have another Harley project at home to tinker with after work.
Ya I know I should get a life but I just like fixing things.
I'll show the progress on the FXWG and pick your brains when I need some help.
Before I even start on the transmission my question is is it doable to change the 1979-85 trans top to the earlier ratchet top or is there a better upgrade than this to fix the ills of the shifting? At the moment he doesn't want to spend the money to upgrade to a 5 or 6 speed.

JohnB445 · #2 05-11-2008, 08:37 AM

Hi Rodney

I am not sure what other type trans, you are refering to.

I have a lot of info on 1980 FXWG. I will be happy to send what

ever will help you. See 2 trans pics.

PS

I also have no life except riding and torturing bikes, tractors and

boat motors. Picture of my 12' x 16' little shop of horrors attached.

I look forward to seeing pics of your project good luck

[IMG]local://upfiles/36456/20ED32179CB2486F83DA01B1D13E3091.jpg[/IMG]

[IMG]local://upfiles/36456/E65005BA382F4498A5D2B2D3CF42B8F7.jpg[/IMG]

[IMG]local://upfiles/36456/9A0B7E03BDA34D8187A5B287942579B8.jpg[/IMG]

Rodney · #3 05-11-2008, 08:47 AM

Thanks for the images John,
I would guess for simplicity's sake repairing the transmission back to OEM would be the best.
You sure have a lot of green around your shop! Nice looking place. [8D]

megawatt · #4 05-11-2008, 09:56 AM

Hi Rodney,
Well, if he doesn't want to drop the bucks for a fancy, super-wizzbang tranny then your other thought of going to a ratchet top is an easy swap as far as I can see. I have two of the rotary plate type transmissions sitting on my work bench. The mounts on both of them look the same as the ratchet top transmissions except my buddies is designed for a rear belt drive so there is more clearance at the primary mount for a pulley/belt. My tranny, off my '79 FXS, appears to have mounts identical to a ratchet top model.
Was he having problems with his transmission not shifting to the gear he selected as well as making bad noises?
My tranny would overshoot to neutral when down shifting from third gear to second gear however, my friend's works perfectly. His has the FL type linkage, mine of course, was set up with the FX linkage but I made my own simple shift arm for it and got rid of the Heim joint linkage.
With all the recent posts about these rotary plate type transmissions having shifting problems, I can understand your interest in changing his to a ratchet top.

Rodney · #5 05-11-2008, 10:20 AM

Quote:

ORIGINAL: megawatt

With all the recent posts about these rotary plate type transmissions having shifting problems, I can understand your interest in changing his to a ratchet top.

yes listening to others with the rotary top and having issues is what got me thinking of doing a switch.
When I rode his bike last year I do remember it was shifting ok but very lose and sloppy.
I'll know more of what he has in a few hours, going to go get the bike now.

Rodney · #6 05-12-2008, 08:08 AM

We got the 80 to my place early Sunday morning.
I just did get this little trailer fixed up to haul a motorcycle, I extended the tonge, installed a tonge jack rebuilt the tail gate and replaced the floor. I still need to replace the tires and wheels and finish the wiring for the tail lights but it was good to go for hauling the Shovel a few miles.

We took the tanks and battery off the scooter at my buddys place and will do the remainder of the work at my garage since I am tooled up for the job.

Rodney · #7 05-12-2008, 09:11 AM

It didn't take long to get the bike tore down, the engine looks to be in good shape other than needing freshened up. The problem area was as I suspected all along the transmission main gear and bearing seized and lack of oil didn't help any [:@]
Only a couple tablespoons in the trans case. [:@][:@]
We have a ratchet top transmission for parts but I am not sure if they will work in his later rotary top case? We'll see what is needed first before we make any decisions.
The plan as of last night is to split the engine cases check the bearings and go from there. I'm all for rebuilding the lower end but the owner feels if the bearings on the pinion and power shafts look good he wants to put it back together. I simply said it's your engine with 28 year old bearings in there I'd be wanting to split the wheels and do it right

everyone has their way of doing things I guess.

kiwidave2 · #8 05-13-2008, 12:26 AM

some parts will work between the ratchet and rotary top, others will not. the FXWG parts book will provide a lot of clues.

The reason for sloppy shifting on the rotary-top is the crappy linkage. Hard or missed shifts are due to worn parts. As you would expect! Nothing wrong with the tranny itself.....got 86,000 miles on my one.

Some clues here:

http://www.jpcycles.com/productgroup...6-E5D2DA870346

http://www.andrewsproducts.com/motorcycle/index.htm

Rodney · #9 05-13-2008, 09:54 AM

Thanks Dave,
anyone with an FX have any advice on changing the gear ratio in the transmission since I'm into this one or leave it as Harley built it and just replace the damaged gears?
We are going to freshen up the 80- nothing fancy just fix it.
At first look the 4th gear and out put bearing is all that really got damaged which is hard to believe!
I think what may have saved the other moving parts is the owner dumped a can of STP in the transmission last fall when it started making noise. It sure made a gooey mess in the primary [:'(]

daven9113 · #10 05-13-2008, 04:26 PM

Rodney,

You make it look too easy! Always wanted to know how to rebuild a 4 spd tranny. One day, I like to do mine. It's getting to the point that buying a new tranny w/warranty is cheaper than getting theparts and putting int the time ito rebuild.

What's your advice for someone who has never done a tranny rebuild? I like to start small and replace seals, etc... I've got a main seal leak, but rather continue to fill then pull her apart, but someday I've got to get it right.

dave