Meavjring Thickness Of Flywheel Thrust Washer

When a set of collars has been selected ana installed on flywheels, install flywheel assembly into right crankcase. Install sprocket shaft roller bearing assembly and bearing washer m sprocket shaft in the order shown in Illus. 62 or 63, and install left crankcase. No gasket is used on crankcase center joint, and joint should not as yet be coated with gasket cement or sealer. Insert stud at top center of cases and two studs at bottom of cases. Install and tighten nuts, to clamp cases securely together.

Now, by pushing back and forth on ends of sprocket and pinion shafts, check flywheel endplay. If no endplay is found, cases will have to be taken apart and thinner thrust collars installed. Reassemble and again check endplay. If it is found that flywheels now have endplay continue check with Harley-Davidson endplay gauge, Part No. 11967-38, as follows: Install endplay gauge on sprocket shaft, and adjust gauge pin to just touch crankcase when flywheel is pressed toward gear case side. Now push flywheel toward left side case and use a thickness gauge to determine amount of flywheel endplay (see Illus. 55). When this has bee,! accurately determined, it is then a simple matter to calculate how much thinner or how much thicker thrust collars must be installed to attain correct endplay (.012" to .014").

After selecting and installing thrust collars of correct thickness, oil main bearings and proceed with final assembly.

Give both faces of crankcase center joint a moderate application of gasket cement or sealer.

After allowing cement or sealer to air-dry a few minutes, assemble crankcases, install all studs, nuts and cap screws and tighten securely. Remember, three of the crankcase studs, the one at top center and the two bottom studs, are drive fit studs that locate crankcases in exact relation to each other. These studs must not be replaced with loose-fit studs. After crankcase assembly is completed, recheck to be sure flywheels have at least the specified minimum endplay.

Installing Generator

Install generator idler gear:

O.H.V. Engine—install idler gear (5), Illus. 64, spacer and lock ring on stud.

Side Valve Engine—install idler gear (11), Illus. 65, fibre thrust washer and lock ring on stud.

The metal shim (.014" thick), used with standard generator fitted with larger diameter drive gear (later O.H.V. Models only), is to be placed directly on cradle with paper shims above. See "Removing Generator," Page 97.

All Models: Inspect generator drive end gasket and if damaged replace with a new one. Secure gasket to generator end with gasket cement or sealer.

If the original number of paper shims are at hand, use them when installing generator. If original paper shims are not available, then start out with three new shims (shim is approximately .004" thick) placed between generator frame and its cradle.

If generator frame has a small oil drain hole near the drive end, be sure holes in shims line up with hole in generator frame and hole in cradle, so drainage will not be blocked. However, some generators may not have a drain hole in frame and in that case disregard holes in shims. Just a small amount of grease applied to shims and cradle will hold shims in place while installing generator.

With shims in place on cradle, install generator and assemble convex washer, lock washer and nut on strap end, but do not tighten nut as yet.

Insert, temporarily, the two long screws that secure generator to timing gear case. Inasmuch as gear case cover is not yet installed, its thickness will have to be taken up by suitable spacers (nuts or collars) under screw heads to permit screws to be tightened. Tighten mounting screws snugly (not tight); then tighten generator mounting strap nut. Now loosen mounting screws to allow generator to adjust itself, and then tighten these screws securely.

Check lash between generator drive gear and idler gear. Try this at several points around gears. If it is found that gears have considerable lash, remove one or more paper shims from underneath generator. Gears must not, however, be meshed so deeply that no noticeable lash can be felt between all teeth as gears are turned.



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