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PostPosted: Sun May 31, 2009 7:05 pm 
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Reason for modification: All all HD Sportster/Buell gearboxes have reportedly got a problem! The main output shaft is hollow and carries inside 2 sets of needle roller bearings that in turn support one of the gear cluster shafts. Both the shafts therefore turn at different speed hence the need for the bearings. The problem is that the outer bearing is fitted in such a way that it gets little or no lubricant from the main box. This can result in the bearings failing. Given current labour and parts prices this will effectively write the bike off!!!!!!!

The Fix: Fitment of the “Maz” Gearbox output grease/oil nipple conversion. This unit is available from The Emporium some where near Manchester.
There is a “cheep skate” alternative for those who should know better but don’t but I will not cover that here.

1) Tools required:
Torx driver, knife, large flat bladed screw driver, socket, Drill, drill bit, small syringe or grease gun, paddock stand (optional) and copper mallet.

2) Parts required:
The “Maz” conversion plug and nipple assembly (approx. £20), HD transmission lube. Given a lathe and the ability to measure accurately the dimensions of the original seal you could machine your own plug up. Maz's part shown below.

Image
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3) Preparation:
Remove the front sprocket cover using the appropriate torx driver.

4) Removing original seal:
Locate the original seal that sits in the middle of the front drive belt sprocket and cut a slot in the centre of the rubber seal. Insert a suitable flat bladed screwdriver and carefully leaver out the seal.

5) Fitting new blank plug and nipple:
When the original seal is removed ensure the all dirt and corrosion has been removed from the end of the shaft. Do not allow any dirt or debris to enter the shaft. With the inner shaft now exposed check for any signs of bearing failure. Any “blueing” of the inner shaft would indicate the outer bearing has at some point over heated and the bearing has, or is about to fail (go to Maz).
If there is no sign of a bearing issue then using the ½ drive socket and the copper mallet carefully drive the plug/nipple assembly in to the end of the output shaft (Nipple pointing outwards). Ensure the plug is fitted straight and does not “cock” over.
Image

Maz designed them with a thou interference fit, as the plug is alloy, and a tight fit, it will expand more than the steel shaft when hot, so in effect, will stay put.

6) Front pulley cover modification:
It is now necessary to drill a hole in the front pulley cover to allow for the grease nipple which will just poke through the cover. This hole need to be big enough to allow access to the nipple but small enough not to allow your trousers to get court in the pulley. I used a centre drill bit as shown because these do not “snatch” on the plastic like twist drills do.
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To identify where exactly to drill just place the cover back in place using the fixings to hold it lightly in place and spin the back wheel (no not by doing a burn out – I am assuming you put the bike on a paddock stand). Now remove the cover and you should have a “witness” mark showing you where to drill.
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The mod can be finished off by fitting a 1/2 rubber blanking grommet in the hole where the nipple is accessed through.
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7) Lubrication methods:
Maz recommends the use of a grease gun filled with HD transmission fluid I use a small syringe fitted with a tight fitting short length of rubber hose. The reason I use a syringe is so that I know exactly how much lube I have put in. LM grease can be used with care. 5cc (of transmission oil or LM grease) on a regular basis should be sufficient.

Image


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PostPosted: Fri Jun 24, 2011 2:09 pm 
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Current ride: xb12x
Location: stafford
hi
where do i but the above part from??


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PostPosted: Fri Jun 24, 2011 2:46 pm 
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Current ride: xb12x
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hi
is anyone going near the emporium soon, and can pick me one of these up
i live in stafford, so ideally someone from round here
ps ive got a ulysses 2006 model

cheers


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PostPosted: Fri Jun 24, 2011 2:46 pm 
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Current ride: Muffin 2001 X1
valerian wrote:
hi
where do i but the above part from??


Maz ......think they are about a tenner but you'll need to pick it up or get somebody else to and post it on to you.

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2001 X1 2009 1125CR 2006 Uly oh and some Chinese/German hybrid


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PostPosted: Fri Jun 24, 2011 7:37 pm 
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anyone going to this openday ive been told about, can pick me one up?


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PostPosted: Fri Jun 24, 2011 7:51 pm 
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or does someone live close to the place and can post me one,
ill do bank transfer, ill chuck in a fiver above and beyond the postage and the cost


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PostPosted: Fri Jun 24, 2011 8:08 pm 
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Location: Manchester
Why dont you just come to the open day ?.......Stafford aint exactly that far :idea:

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Mithered ta death.
92 MB
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98 S1W
00 M2
01 X1
03 P3
10 CR


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PostPosted: Fri Jun 24, 2011 8:47 pm 
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when is it?


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PostPosted: Fri Jun 24, 2011 8:52 pm 
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Current ride: Buell X1 2001
Location: southampton
viewtopic.php?f=5&t=11338

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2001 X1 :4roz:


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PostPosted: Fri Jun 24, 2011 9:05 pm 
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Current ride: xb12x
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shit
working that day
is it open on any saturday?


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PostPosted: Fri Jun 24, 2011 9:36 pm 
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Location: Manchester
Every Saturday and most Sundays.

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR


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PostPosted: Fri Jun 24, 2011 9:43 pm 
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Current ride: xb12x
Location: stafford
what times mate?
and u have got em in?
how much
cheers


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PostPosted: Fri Jun 24, 2011 9:50 pm 
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Mon-Sat 10am to 7pm, Sundays (when no F1 on the box) midday to 6ish.

0161 343 3077

Yes, I have plenty in stock and they're a tenner each.

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR


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PostPosted: Sat Jun 25, 2011 10:51 pm 
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Joined: Wed Apr 20, 2011 11:48 pm
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Current ride: xb12x
Location: stafford
fitted this mod earlier
i have to say it went in no problem but it certainly wasnt flush like the seal was, it went in about 1.5.mm further, doesnt appear to have made any difference
is this an issue?
also the wheel turns freely and silently likeit did b4


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PostPosted: Sat Jun 25, 2011 10:56 pm 
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Location: Manchester
Why did you continue to fit it deeper than flush ??????????????

_________________
Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR


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