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Discussion Starter · #1 ·
Hey guys just picked up an 87 1100 Sporty with a "bad transmission" for 600.00. Bike sat for 15 years in a shed.

Tore the transmission out yesterday hoping to find a broken shift cam follower but found 3rd gear blown instead. This got me thinking, why would you park it for 15 years if all you lost was 3rd gear? Hell, I'd ride around with 3 out of the four gears but that's me.

So today I attempted to pull the cam cover do do some inspecting and I noticed the main gears kept sticking to the cover as I worked it off. Usually I use a putty knife to push them back and continue to work the cover off. Finally decided I would just pull it off and deal with timing it later. As you more experienced guys know, the main gear don't move unless the facking shaft is broken. Lesson learned.

Now my question is, how the hell do you get the shaft out? I removed the retainer/clip washer and that's where I'm at.

Any tips, advice, sources for the shaft? I've been googling for an hour and got nothing.

Thanks in advance!
 
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Tore the transmission out yesterday hoping to find a broken shift cam follower but found 3rd gear blown instead. This got me thinking, why would you park it for 15 years if all you lost was 3rd gear? Hell, I'd ride around with 3 out of the four gears but that's me.
That would really be a BAD idea.....

If there is damage done in the tranny and was not addressed ASAP ....
The Tranny could blow out the case and super big time damage would then be seen....:eek:

But...With a broken pinion shaft....It ain't going to run anyway....
Take a look at the pump gear to see "IF" it was installed backwards....If so....That could cause the shaft to fail...

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Discussion Starter · #4 ·
That would really be a BAD idea.....

If there is damage done in the tranny and was not addressed ASAP ....
The Tranny could blow out the case and super big time damage would then be seen....:eek:

But...With a broken pinion shaft....It ain't going to run anyway....
Take a look at the pump gear to see "IF" it was installed backwards....If so....That could cause the shaft to fail...
Was half-assed kidding with that statement. Just a little frustrated but thats the fun in this right? ;)

So the answer is total tear down of the bottom end? That puts me about a foot over my head but I'm willing to learn. Got an old school harley wrench buddy that's almost been persuaded to take me in...if I keep bringing him burgers on my lunch breaks.
 
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With all due respect, can I get a second?
Here is a third....

No way to get to the pinion shaft nut...
Not only will you need to break down the flywheel ass....
But, you will need to true the wheels back up after the shaft has been replace...

Take a look at post 74 in this thread......

http://www.jockeyjournal.com/forum/showthread.php?t=95018&page=4

The photos will show you what you will need to contend with.....

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Stew, are the 87 XL bottom ends even servicable? I'm not up on that year but it seems to me I've read that they aren't. No taper on the pinion? I know I've read about 87 pinions before. Maybe head over to S&S or T&O and dump a grand right off the bat and save a huge headache.
 
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Forgot about dat...^^

They are still on tapers up to the 85 year models

86-up are a three piece (Two Flywheels and a Crank-Pin), with the pinion and sprocket shafts made into the wheels...No longer a 5 piece built-up crank.
Which is what he may have going on with his wheels...
Crank-pin still on taper's

In 2004 they started doing the press deal like the Twin Cams and the XR-750's.
Those are meant to be a "BIC" lighter, although they can still be serviced.

He needs to pull his motor down and see what needs are going to be at hand...

T&O has been taking the OEM wheels with the shafts made as one piece, and converting them to a plug in shaft like the older models had....
This just may be the ticket for his problem...
A call to T&O would tell the story....

http://www.truettandosborn.com/

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Stew, are the 87 XL bottom ends even servicable?
No taper on the pinion? I know I've read about 87 pinions before.
Indeed....

Did a bit of digging....

T&O can machine the OEM wheel for a plug in shaft....
The shaft is Special made for the 1986-2003 Sporties by S&S
PN for that shaft is 33-2325 comes as a kit with pinion shaft nut, key and a metering plug orifice drilled to 0.0626
The shaft does not need the inner race, being it's made as a one piece shaft.

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Sure sounds to me like a good time to add some stroke.....
Motor all the way down..
Needing flywheel work done to the OEM wheels anyway...

Lets see.....Hummmmmm

New set of wheels ....Stroke of Choice..(4-1/2 is a Near stock Motor life)
Will need both shafts and perhaps a fresh crank-pin..
Pistons for the stroke....Being they will be needed, an clean-up bore to the next size up..

.....Done Deal.....

Options..
H-Beam Rods....
Heads...Being it is an 1100cc .... They are somewhat of a Bad-Boy out of the Box.
Harley de-tuned them for the 88 and up 1200cc motors...

Guys..... Am I leaving out anything else..??

O-Yeah...The Cams....Would be nice to be able to feed those Bigger Cubes...
Well-Hell....Saying that....
A Super-E carb would come in handy to do that too...

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Discussion Starter · #15 ·
T&O has been taking the OEM wheels with the shafts made as one piece, and converting them to a plug in shaft like the older models had....
This just may be the ticket for his problem...
A call to T&O would tell the story....

http://www.truettandosborn.com/
Just got off the phone with T&O...

$100 for machine work
$215 for S&S Shaft

Gonna need new rod bearings and true everything up.

Gonna get an estimate on rebuild from my guy at lunch. :confused:

Yep, it could be one expensive 600 bike. I did find a local 86' motor for 1500.

Is there much interest in these 1100's if I were to part the motor out?

Thanks guys!
 

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My father has an 87 1100 and that thing boogies! I'd make the repairs and have a good time. You should still come out ahead in the long run. Of course it's your choice. It's still a lot of work.
 

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Forget doing a stroke to the Evo Sporty's....
It can not be done using the stock Rods with their short Center to Center...
Would be in need of longer Rods and Jugs...
That would be up there in Dollars....
$100 for the machine work from T&O seems pretty reasonable to salvage that bottom end, no? Lots of work but it might be a fairly painless($) fix.
 
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With-out a Doubt it would be the way to go, with what he has to work with....

Could find a used crank from the 86 to 90 models, but the need would probably be there to rebuild it too...???

Is there much interest in these 1100's if I were to part the motor out?
As far as parting the bike out....
Would most likely get your money back and then some...

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And being the lower end is going to be all apart....Should do a Balance Job to it also..

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Discussion Starter · #20 ·
$100 for the machine work from T&O seems pretty reasonable to salvage that bottom end, no? Lots of work but it might be a fairly painless($) fix.
Saw my guy at lunch. $1500 to rebuild it probably using most of the old parts. Motor only has 8k on the clock. He seems to think it will mostly all fall within tolerance and be reusable. I would need to source a crank assembly to get the pinion shaft.

Here's my current options:

1. Have him do rebuild making payments as money comes through. Probably a couple months at best. New baby eating me out of house and home as well as my 14 year old boy.

2. Sell him bike for 1000.00 and walk away with 400. He needs a couple weeks to free up the money as well.

3. Part the whole thing out one piece at a time. Deal with shipping and buyers - good times. :rolleyes:

4. Buy the motor I mentioned earlier for 1500.00. Come to find out it's an 86 1200.

5. Do the rebuild myself. Estimated time to delivery: 2 years LOL.
 
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